Beer Process

Generic Hazard Analysis
and
Critical Control Points
(HACCP)
Plan for the
Canadian Brewing Industry
A Project of
Brewers Association of Canada
HACCP Working Group
Revision Date: November 2009
www.brewers.ca
Table of Contents
Introduction.............................................................................................................5
HACCP Principle 1 - Hazard Identification.............................................................9
HACCP Principle 2 - Critical Control Points..........................................................10
HACCP Principle 3 - Critical Limits.......................................................................11
HACCP Principle 4 - Establish Monitoring Procedures........................................11
HACCP Principle 5 - Establish Deviation Procedures..........................................13
HACCP Principle 6 - Establish Verification Procedures.......................................14
HACCP Principle 7 - Establish Record Keeping/Documentation.........................15
BAC Generic HACCP Program.............................................................................17
Form 1: Product/Process Description..................................................................19
Form 2: List of Product Ingredients and Incoming Materials...............................23
Form 3: Process Flow Diagram...........................................................................27
Form 4: Schematic Diagram................................................................................41
Form 5: Hazard Identification Biological Hazards................................................45
Form 6: Hazard Identification Chemical Hazards................................................57
Form 7: Hazard Identification Physical Hazards..................................................69
Form 8: Critical Control Points.............................................................................81
Form 3A: Process Flow Diagram with CCPs.....................................................127
Form 5A: Biological Hazards Control & CCPs...................................................141
BAC Generic HACCP Model

Revision Date: November 2009 Page 3 of 252
Table of Contents (Continued)
Form 6A: Chemical Hazards Control & CCPs...................................................153
Form 7A: Physical Hazards Controls & CCPs...................................................167
Form 9: Hazards not Controlled by Brewery.....................................................181
Form 10: HACCP Plan.......................................................................................185
HACCP Plan Appendices....................................................................................193
Appendix 1- Form 3 - Information used for Flowcharts......................................195
Appendix 2- Form 8 Critical Control Points.....................................................213
Appendix 3 - Form 10 - Additions for Low Alcohol Beer.....................................217
Appendix 4 Diagrams for Hazard Identification & CCP Decision Tree............221
Appendix 5 BAC Glass Inclusion Reference...................................................225
Appendix 6 Blank Forms 1 - 10.......................................................................229
Appendix 7 Reference Literature.....................................................................243

Introduction
HACCP (Hazard Analysis Critical Control Point) systems are required under
proposed Health Canadas Good Manufacturing Practices Regulations for Food.
Specifically, manufacturers must develop procedures to ensure products
manufactured do not pose a health risk.
The HACCP program is a world-wide recognized systematic and preventative

approach that addresses biological, chemical and physical hazards through
anticipation and prevention, rather than by finished production inspection.
This document is a working guide to preparing a customized program of hazard

analysis and identification of critical control points (CCP) for brewers, as an aid to
consistent compliance and inspection by the Canadian Food Inspection Agency
(CFIA). This document is not a customized model per se. Each brewer using this
working guide is responsible for producing his or her own customized model.
Prior to the development and implementation of a HACCP program,

establishments must have developed, documented and implemented programs
to control factors that may not be directly related to manufacturing controls but
support the HACCP plans and the Good Manufacturing Practices (GMP). These
programs are called Pre-requisite programs. These are discussed in detail in
another document (see BAC- Generic Pre-requisite Programs).
There are 12 basic steps to implementing a HACCP program. They are:
1. Assemble the HACCP team;
2. Describe the product;
3. Identify intended uses;
4. Construct process Flow Diagram and Plant Schematic;
5. Verify on site the Flow Diagram and Plant Schematic;

Introduction (Continued)
6. List hazards associated with each step (Principle 1);
7. Determine Critical Control Points (Principle 2);
8. Establish Critical Limits (Principle 3);
9. Establish Monitoring Procedures (Principle 4);
10. Establish Deviation Procedures (Principle 5);
11. Establish Verification Procedures (Principle 6); and
12. Establish record keeping/documentation for Principles one through six

(Principle 7).
This manual deals in detail with steps 1 through 8, which include Principles 1
through 3 of HACCP system elements. It also discusses in general terms the
follow-up requirements that make up steps 9 through 12.

Instructions for Companies
It is suggested that the user of this document becomes acquainted with the BAC
Food Safety Toolkit Introduction document before attempting to proceed with
applying the recommendations herein.
There are also other BAC guidance documents that are to be used along with
this BAC - Generic HACCP Plan model. They are:
BAC/HACCP Plan Workbook; and
BAC/HACCP Plan Glossary.
Pre-requisite programs should be established before attempting to implement the

HACCP program.
Each company will determine the appropriate internal procedures to follow to

ensure that the programs are implemented as described and are effective.
Reminder - This document is not a customized model per se. Each brewery using
this working guide is responsible for producing its own customized HACCP
program.

HACCP Working Group Members
The BAC HACCP Working Group was established under the direction of the
Product Integrity Committee of the Brewers Association of Canada.
These Pre-requisite Programs have been developed by the Brewers Association

of Canada (BAC) with a Technical Committee comprised of industry members,
government representatives and food safety consultants. The BAC
acknowledges the committee members for their outstanding contribution to the
BAC/HACCP project.
We also extend our appreciation and gratitude to Agriculture and Agri-
Food Canada and the Canadian Food Inspection Agency for their financial
and technical support of this project.
Mr. B. Andrews Molson Canada
Ms. E. Bounsall Brasserie McAuslan
Ms. S. Buttenham Sleeman Breweries Ltd.
Ms. M. Dewar Brewers Association of Canada
Dr. T. Dowhanick Labatt Breweries of Canada
Ms. A. Fuller Great Western Brewing Company
Mr. L Harford Brewers Association of Canada
Mr. M. Ligas Magnotta Brewery
Mr. G. Muise Pump House Brewery
Mr. R. Savage Molson Canada
Mr. A. Kassianenko Canadian Food Inspection Agency
Mr. G. Sundeen Canadian Food Inspection Agency
Mr. F. Schreurs Guelph Food Technology Centre
Mr. P. Medeirois Guelph Food Technology Centre
Mr. K. McMillan Guelph Food Technology Centre
Ms. A. Brown Guelph Food Technology Centre
Ms. M. Harris-Bailey Guelph Food Technology Centre

HACCP Principle 1 - Hazard Identification
Principle 1: Conduct a hazard analysis.
A product safety hazard is any biological, chemical, or physical

property that may cause beer to be unsafe for human consumption.
Breweries determine the product safety hazards and identify the

preventive measures the plant can apply to control these hazards.
On the basis of available information for each of the ingredients used in beer and
for each of the process steps in brewing, potential biological, physical and
chemical hazards are identified. Information sources include published
databases, scientific literature, company records, external and internal audits etc.
In addition to identifying potential hazards, Forms 5, 6 and 7 are used to identify
the control points.
Diagrams for Hazards Identification and CCP Decision Tree
Critical Control Points for breweries are determined using the HACCP Decision
Tree. The Decision Tree was first developed by a Codex Alimentarius working
group on HACCP in June 1991. This Decision Tree has been slightly modified to
include a prescreening question and preliminary instructions.
Pre-screening question = Determine if (hazard) fully controlled by Pre-requisite

Programs. If yes, indicate Pre-requisite Program(s) and proceed to the next
identified hazard. If no, proceed to Question 1. (See Appendix)

HACCP Principle 2 - Critical Control Points
Principle 2: Identify critical control points.
A critical control point (CCP) is a point, step, or procedure in a food process at

which control can be applied and, as a result, a food safety hazard can be
prevented, eliminated, or reduced to an acceptable level.
Using the Decision Tree, Form 8 is completed. The last column is where Critical
Control Points are identified. CCPs are labelled numerically with a category
qualifier for Biological, Physical and Chemical (B, P or C) hazard and expected
outcome of the control measure (elimination of risk(e), prevention (p), or
minimize or reduce (r)). In this model , the Critical Control Points in breweries were identified
as follows:
Step CCP #
Empty Bottle Inspection CCP1-P
Empty Bottle Inspection/ Residual Liquid Detector CCP1-C
Filling (Auto-Flush Only) CCP2-P
Internal Cleaning (Manual) CCP3-C
Hazards identified on Forms 5, 6 and 7 are either controlled at some point in the
brewing process or cannot be controlled by the facility. Form 9 is intended to
identify control measures that do not take place in the brewery but are controlled
elsewhere. No such hazards were identified in the analysis of breweries.

HACCP Principle 3 - Critical Limits
Principle 3: Establish critical limits for each critical control point.
A critical limit is the maximum or minimum value to which a

physical, biological, or chemical hazard must be controlled at a
critical control point to prevent, eliminate, or reduce to an
acceptable level.
For each Critical Control Point, critical limits were established. These are values
which separate acceptability from unacceptability. They are intended to meet
government regulations, industry standards or other scientific data.
HACCP Principle 4 - Establish Monitoring Procedures

Principle 4: Establish critical control point monitoring requirements.
Monitoring is the act of conducting a planned sequence of observations or

measurements of control parameters to assess whether a CCP is under control.
Monitoring activities are necessary to ensure that the process is

under control at each critical control point. Each monitoring
procedure and its frequency will be listed in the HACCP plan.
At each CCP, the monitoring requirements and the means to ensure that the CCP
remains within the critical limits are specified. Monitoring procedures generally
relate to on-line processes and are usually by observation or by measurement.
The frequency of testing, who is responsible for carrying out the testing, and the
testing procedures must also be specified. The monitoring specifications are
written on Form 10 for each CCP. Each brewery will develop its own
specifications, where required.
Monitoring tracks the system's operation and allows for action to be taken in the
event of a loss of control or where there is a trend toward the loss of control. It
provides information to a brewery on a timely basis, allowing for decisions on the
acceptability of the lot at a particular stage in the process. Monitoring procedures

HACCP Principle 4 - Establish Monitoring Procedures (Continued)
performed in the establishment during operation will result in written

documentation that will serve as an accurate record of the operating conditions.
If any of the critical limits is out of control as determined by the monitoring

procedures, the CCP will be out of control. Lack of control at a CCP is defined as
being a critical defect or a deviation. Deviations will result in the production of a
hazardous or unsafe product Therefore, adequate and effective monitoring
procedures are essential due to the serious consequences arising from
deviations. Most monitoring procedures for CCPs must be rapid because they
relate to on-line processes and there is not sufficient time for lengthy analytical
testing. Physical and chemical measurements or visual observations are
preferred because they can be done rapidly. All monitoring equipment must be
properly calibrated for accuracy. Examples of some physical and chemical
measurements taken to monitor the critical limits are: temperature, time and pH.
There are many ways to monitor critical control points. Monitoring can be done
on a continuous or batch basis. The reliability of continuous monitoring (100 % is
preferred where feasible). The established monitoring frequency must be
sufficient to substantiate that the hazard is under control. Responsibility for
monitoring is clearly identified and individuals monitoring the CCPs must be
trained in the testing procedure and must fully understand the purpose and
importance of monitoring. The individual must have ready access to the
monitoring activity and must be unbiased in monitoring and reporting. Finally the
individual must accurately report the monitoring activity.
All operational records and documents that are associated with CCP monitoring
must be properly completed and signed by the person doing the monitoring and
verified/signed by a responsible official of the company.

HACCP Principle 5 - Establish Deviation Procedures
Principle 5: Establish corrective actions.
These are actions to be taken when monitoring indicates a

deviation from an established critical limit. The final rule requires a
plant's HACCP plan to identify the corrective actions to be taken if a
critical limit is not met. Corrective actions are intended to ensure
that no product injurious to health or otherwise adulterated as a
result of the deviation enters commerce.
A deviation is defined as failure to meet the specified critical limits. Deviation

procedures are pre-determined and document the set of corrective actions that
are implemented when a deviation occurs.
All deviations must be corrected by taking appropriate corrective action(s) to

control the non-compliant product and to correct the cause of non-compliance.
The corrective action(s) taken must be recorded and filed.
A deviation procedure must describe the acceptable corrective action(s) for a

deviation. The diversity of possible deviations at each CCP means that more than
one corrective action may be necessary at each CCP. The corrective action(s)
must correct the cause of the deviation and must control the actual or potential
hazard resulting from the deviation. Product control includes proper identification,
and handling of the affected lots. The deviation procedures at each CCP are
written on Form 10. These procedures will be developed by each brewery in
accordance with the brewerys requirements.
Corrective actions are prescribed and formalized so that employees responsible

for critical control point monitoring understand and are able to perform the
appropriate corrective action(s) in the event of a deviation.

HACCP Principle 5 - Establish Deviation Procedures (Continued)
When a deviation occurs, it will most likely be noticed during the routine
monitoring of a CCP. A deviation results when the pre-determined critical limit for
a CCP is out of compliance. If the proper corrective action is not taken the
deviation may result in an unacceptable health risk.
HACCP Principle 6 - Establish Verification Procedures
Principle 6: Establish procedures for verifying the HACCP system is working as

intended.
Validation ensures that the plans do what they were designed to do;
that is, they are successful in ensuring the production of safe
product. Plants will be required to validate their own HACCP plans.
Verification ensures the HACCP plan is adequate, that is, working

as intended. Verification procedures may include such activities as
review of HACCP plans, CCP records, critical limits and analytical
data
Verification activities are methods, procedures and tests used to determine if the
HACCP plans for that establishment are valid and are operating properly.
Verification activities are generally involved and may include analytical testing. In
carrying out the verification activities, the establishment may find that some
hazards were overlooked or they may discover new or unexpected hazards. In
this case, the plan needs to be modified appropriately. The verification
procedures at each CCP are written on Form 10 by each brewery in accordance
with the brewery requirements. Both the establishment and the CFIA will have a
role in verifying HACCP plan compliance and will carry out activities to verify that
the HACCP plan is operating properly. Verification activities differ from monitoring
activities. Results from verification activities are not intended to make decisions
on the acceptability of lots of product. Verification activities involve for example,
analytical testing or auditing of the monitoring procedures, product sampling,
audits of monitoring and verification records.

HACCP Principle 7 - Establish Record Keeping/ Documentation
Principle 7: Establish record keeping procedures.
The HACCP program requires that all plants maintain certain

documents, including its hazard analysis and written HACCP plan,
and records documenting the monitoring of critical control points,
critical limits, verification activities, and the handling of critical limit
deviations.
The HACCP records are defined as the record keeping that is done at each CCP
and that contain the information required to ensure that the HACCP plan is
followed.
Records are essential in determining the compliance of the establishment in

following the agreed-upon HACCP plan. The HACCP records differ from the
records that are kept to ensure compliance to the pre-requisite program
requirements. The required HACCP records to be kept at each CCP are written
on Form 10 by each brewery in accordance with the brewery requirements.
Monitoring results are documented together with any deviations and corrective
action taken. Failure to document the control of a CCP would be a critical
departure from the HACCP plan. Verification activities are also to be recorded.
Records must specify who recorded the information and must indicate who
reviewed and signed off the information.
A record may be in any form (processing chart, written record, computerized

record) and show the historical record of the process, the monitoring, the
deviations and the corrective actions (including disposition of product) that
occurred at the identified CCP. The information contained in the records is used
to establish the product's processing profile that would be used if there are any
subsequent problems. Accurate records allow for trace back of the actual
manufacturing conditions which will aid in troubleshooting if a problem arises.

HACCP Principle 7 - Establish Record Keeping/ Documentation
(Continued)
The importance of records to the HACCP program must be emphasized. The

records are an important tool that is used to ensure that the establishment is
following the agreed upon HACCP plan. It will be imperative that the
establishment maintain up-to-date, properly filed, and accurate records.

BAC GENERIC HACCP
PROGRAM

FORM 1:
PRODUCT/PROCESS
DESCRIPTION

HACCP Plan - Form 1
Page 1 of 1
Title: Form 1 Product Description

BAC Generic Completed By: BAC TC Date:
Approved By: BAC TC Date:
Process/Product Name: BEER
1. Product Name(s) Beer, Ale, Stout, Malt Liquor

As defined in the Food and Drug Regulations B.02.130 to
B.02.132.
2. Important Product 3
Characteristics
(aw, pH, PRESERVATIVES..)
3. How it is to be used Consumer product - Alcoholic beverage
4. Packaging Glass bottles

Lined aluminum bottles
Lined cans
Stainless steel kegs
Plastic bottles (PET etc.)
5. Shelf Life Shelf Life Information required.
6. Where it will be sold Government sales provisions apply - licensed retailers, hotels
etc.
On premise and off premise
7. Labelling Instructions Food and Drug Regulations (i.e. alcohol content labelling)
Consumer Packaging and Labelling Legislative/Regulatory
requirements
Claims allowed by Health Canada (i.e. energy value)
8. Special Distribution Inspection done on third party carriers and carriers dedicated to
Control food

FORM 2:
LIST OF PRODUCT
INGREDIENTS AND
INCOMING MATERIALS

HACCP Plan - Form 2
Page 1 of 1
Title: Form 2 -
BAC Generic List of Product Ingredients and Incoming Materials
Completed By: BAC TC Date:
Product Name: BEER

LIQUID INGREDIENTS DRY INGREDIENTS PRIMARY PACKAGING
(allowable) MATERIALS
Potable water Barley malt B C P New Glass P

- City Water B C P Wheat malt B C P Used glass B C P
- Well/ Surface Water B C P Hops BC P Lined aluminum cans P
- Purchased Water B C Cereal grain e.g. wheat Lined aluminum bottles P
(non-malted), corn, oats,
New stainless steel kegs P
rice B C P
Used stainless steel kegs None
Plastic bottles e.g. PET None
Crowns , Closures and Can
Ends None
OTHER INGREDIENTS OTHER INGREDIENTS OTHER INGREDIENTS (allowable)
(allowable) (allowable)
Caramel C P Preservatives C Yeast B C
Dextrin C P - Ascorbic Acid, Calcium Carbohydrate matter, e.g.
Ascorbate, Potassium sucrose, syrup Honey
Food enzymes C
Metabisulphite, Sodium
Salt C P
- Amylase, Glucoamylase, Metabisulphite
Glucanase, Papain, Hop oil C P
Yeast foods C
Pentosanase, Protease
- Manganese Sulphate, Hop extract C P
Stabilizing agents C
Phosphoric Acid, Zinc Carbon dioxide C
- Calcium Alginate, Sulphate, Ammonium
- Purchased CO2
Carrageenan, Propylene Persulphate (brewers yeast)
Glycol Alginate - Regenerated CO2
Processing aids B C
Water preparation Liquid wheat extract C P
- Irish Moss Seaweed;
agents C Activated Carbon; Nitrogen/ Oxygen/ Compressed
- Ammonium Phosphate, Magnesium Silicate; Air C
dibasic, Calcium Chloride, Cellulose; China Clay;
Calcium Hydroxide, Diatomaceous Earth; Gelatin;
Calcium Sulphate, Citric Silica Gel;
Acid, Lactic Acid, Polyvinylpolypyrrolidone;
Magnesium Sulphate, Wood Shavings derived from
Phosphoric Acid, oak, beech, hazelnut or
Sulphuric Acid cherry wood;
Dimethylpolysiloxane (wort),
Hydrogen Peroxide (mash);
B/ C/ P = Biological (B) or Chemical (C) or Physical (P) hazard(s) identified.

FORM 3:
PROCESS FLOW DIAGRAM

HACCP Plan - Form 3
BAC GENERIC HACCP PLAN FORM 3
Approved By: BAC HACCP Technical Committee

Approval Date:
Total # of Pages Including Key = 12
Page 1 of 12
KEY
Box with no fill = Process Step
Blue Filled Box = Input
Yellow Filled Box = Output
Dotted Line = Optional Step
Red Filled Circle = Last step in process
Open-ended Box = Chemical/ Material used

that is not an ingredient or processing aid
that does not contact the product directly .
B Biological Hazard identified at this step
C Chemical Hazard identified at this step
P
Physical Hazard identified at this step

HACCP Plan - Form 3
MASTER FLOWCHART OF
MAJOR PROCESS STEPS (PS) FOR MAKING BEER (Page 2 of 12)
RECEIVING FULL TANKER

(PS1) B C P (Step T6) B C
FULL TANKER
STORAGE & HANDLING UNLOADING
(Step PS2) B C P (Step T7) B C
Water & Dry

BREWING
Ingredients
(Step PS3) C
MILLING/ MASHING/ LAUTERING
KETTLE/ WHIRLPOOL/ COOLING
Yeast,
Processing
Aids FERMENTATION
(Step PS4) C
Processing
Aids, CO2 AGING
(Step PS5) C
CLARIFICATION/ FILTERING
BRIGHT BEER STORAGE

(Step PS6) C
BRIGHT BEER
Bottles, Cans, Kegs, PROCESSING
Crowns, Tankers (Step PS7) C
New
Bottles
Prep
PS8 (NB) PACKAGING
CP (Step PS8)
BOTTLING CANNING KEGGING TANKERING

Step PS8 (BT) C P Step PS8 (C) B C Step PS8 (K) C Step PS8 (T) B C
Returned
Bottles
Prep
PS8 (RB) - Washing
BCP - Rinsing - Cleaning
- Inspection
- Filling - Filling - Filling
- Filling
- Packing - Palletizing
- Flushing
WAREHOUSING/ SHIPPING
(Step PS9)

HACCP Plan - Form 3
PS3 - BREWING (Page 3 of 12)
RECEIVING
(Step B1) B C P
Storage
(Step B2) B C P
Milling
(Step B3) C
Cereal Cooker
(Step B4)
Mashing
(Step B5)
Lautering
(Step B6)
Holding Tank
(Step B7)
Kettle
(Step B8)
Whirlpool
(Step B9)
Oxygen
Wort Cooling
(Step B10)
Next Process - PS4

Fermentation

HACCP Plan - Form 3
PS4 - FERMENTATION (Page 4 of 12)
COLD WORT
WORT OXYGENATION/
Oxygen/ Sterile WORT AERATION
Air (Step F1 )
Yeast Propagation
(Step Y1)
Yeast Storage
(Step Y2)
Acid Washing
(Step Y3)
FERMENTATION
YEAST
(Step F2)
CO2
Cooling
(Step F3) C
Yeast
Removal
GREEN BEER
(Step F4)
BAC Generic HACCP Model Next Process - PS5 -Aging/

Revision Date: November 2009 Page 32
Clarification/ Filtration of 252
HACCP Plan - Form 3
PS5 - AGING/ CLARIFICATION/ FILTRATION (Page 5 of 12)
GREEN BEER COOLING

(Step A1) C
Buffer tank
(Step A2)
Centrifuge
(Step A3)
Yeast,
By-products
Processing aids,
Stabilizers,
CO2, Preservatives Buffer tank
(Step A4)
CO2
Cooling tank
(Step A5) C
CO2, Hops
Aging Tank
(Step A6) C Beer,
Spent Hops, CO2
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives Secondary Storage
(Step A7) C CO2, Spent
Yeast
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives Surge/ Buffer Tank
(Step A8) C
CO2
Caramel & other
ingredients,
Processing aids,
Stabilizers, CO2,
Preservatives Filtration
(Step A9) C
CO2, Spent
Yeast
Deaerated water,
CO2, Nitrogen
Bright Beer Storage
(Step A10 = PS6) C
CO2
Next Process - PS7 -

Bright BeerProcessing

HACCP Plan - Form 3
PS7 (BBP) - BRIGHT BEER PROCESSING (Page 6 of 12)
PS7 (SF) PS7 (P)

STERILE FILTRATION FLASH PASTEURIZATION
Bright Beer Tank Bright Beer Tank

(Step SF1) C (Step FP1) C
CO2
Filtration Flash Pasteurization
(Step SF2) C (Step FP2) C
Sterile Beer Tank Pasteurized Beer Tank

(Step SF3) (Step FP3)
Next Process - PS8 -Packaging Next Process - PS8 -Packaging

HACCP Plan - Form 3

HACCP Plan - Form 3
Process Step 8
PS8 (RB) - RETURNED BOTTLES PREP (Page 7 of 12)
Receiving/ Storage
(Step RB1) P
Caustic
De-Palletizing Hydro Jet Sprays

(Step RB2) P (Step RB8) B C P
De-Casing & Inspection

(Steps RB3-4) P
Post Soak
(Step RB9 C P
Bottle Wash Loading

(Step RB5) P
External Flush
(Step RB10) P
Pre-Rinse
(Step RB6) P
Water, External Rinse

Chemicals & (Step RB11) P
Steam
Soak Tanks (caustic)
(Step RB7) C P
Water
Interior Rinse
(Steps RB12) C P
Water
FINAL RINSE
(Step RB13) C P
Next: (PS8- BT) Bottling

HACCP Plan - Form 3
Process Step 8
PS8 (NB) - NEW BOTTLES PREP (Page 8 of 12)
Receiving
(Step NB1) P
Preliminary Inspection
(Step NB2) P
Storage
(Step NB3-6) P
Inspection
(Step NB7) P
RINSE
(Steps NB8-9) C P

HACCP Plan - Form 3

HACCP Plan - Form 3
Process Step 8
PS8 (BT) - BOTTLING (Page 9 of 12)
BOTTLES - See
Returned Bottles Prep
& New Bottle Prep Air
Empty Bottle Inspection
(Steps BT1) C P Drying
Water
(Step BT11)
Down Bottle Filler In-Feed Control

(Steps BT2) P
Label & Code

Bright Beer, (Steps BT12-13)
CO2, Compressed Air
Filling
Water (Steps BT3-5) C P
CO2,
Glass
Filled Bottle Inspection
(Step BT14)
Crowns, Compressed Air
Crowning
Water (Step BT6 ) C P
Packing & Sealing

Bottle Flush (External) (Steps BT15-18)
Water (Steps BT7-8)
Steam Pasteurize Secondary Code & Full Case

& Chemicals (Step BT9) Inspection
(Steps BT19-20)
Foam Inspection/ Candling

(Step BT10) P Palletize
(Step BT21)
Storage
(Step BT22)
Live Load
SHIPPING
(Step BT23)

HACCP Plan - Form 3

HACCP Plan - Form 3
Process Step 8
PS8 (K) - KEGGING (Page 10 of 12)
KEGS
Receiving
(Step K1)
Racking
(Step K7)
Filling (Step K18) C
Storage, Handling,
De-palletizing
(Steps K2-3) Internal Cleaning Internal Cleaning
Manual Automated Barnes Neck Wash &
(Steps K8-12) C (Steps K8-12) C Sanitize
(Step K19-21)
External Inspection
(Step K4 )
Sterilize & Hold Dust Cap Applied

(Step K13) (Steps K22)
External Cleaning
(Steps K5-6)
Purge to Empty &

Air Dry
Counter Pressure
(Step K23)
(Steps K14-15)
Barnes Neck Sanitize & Code

Inspect (Step K24)
(Step K16-17)
Weigh & Palletize

(Steps K25-26)
Storage
(Step K27)
Live Load
SHIPPING
(Step K28)

HACCP Plan - Form 3

HACCP Plan - Form 3
Process Step 8
PS8 (C) - CANNING (Page 11 of 12)
CANS
Receiving Drying (Steps C16-17)
(Step C1)
Coding
(Step C6)
Storage & Handling
Fill Height Inspection
(Step C2) B C
(Step C18)
Rinser
Depalletizing/ Pallet ID (Step C7) C
(Steps C3-4 )
Divert to Packers
(Steps C19)
Bright
Beer, Filling
Inspection CO2 (Steps C8- 10)
(Step C5)
CO2
Hi Cone Machine
(Step C20)
Can Ends
Seaming
(Steps C11-13) C
Case Packers
Water (Steps C21)
External Flush
(Step C14)
Pastuerizer Inspection
(Step C15) (Step C22)
Tray Machine & Code

(Steps C23-24)
Palletize
(Step C25)
Storage
(Step C26)
Live Load
SHIPPING
(Step C27)

HACCP Plan - Form 3

HACCP Plan - Form 3
Process Step 8
PS8 (T) - TANKERING (Page 12 of 12)
Empty Tanker
(Step T1) C
Caustic, Water,
Acid
Tanker Washing
(Step T2) C
CO2
Tanker Purge
(Step T3) C
CO2
Bright Beer,
CO2
Tanker Filling
(Step T4) B C
Tanker Shipping
(Step T5)
Full Tanker Receiving

(Step T6) B C
FULL TANKER UNLOADING

(Step T7) B C

FORM 4:
SCHEMATIC DIAGRAM

HACCP Plan - Form 4
Page 1 of 1
Title: Form 4 Schematic Diagram

Note: Each brewery must be individually assessed at the time of implementation to ensure identified
hazards have been addressed.
Schematic Diagram
TO BE COMPLETED

FORM 5:
HAZARD IDENTIFICATION
BIOLOGICAL HAZARDS

HACCP Plan - Form 5
Title: Form 5 Hazard Identification - Biological Hazards

List all biological hazards Identified biological Controlled at:

related to ingredients, hazards (Bacteria,
incoming material, parasites, viruses,
processing, product flow, etc.)
etc.
INGREDIENTS
LIQUID INGREDIENTS
City Water Coliform, E. Coli
Purchased Water Coliform, E. Coli
Well/ Lake/ Surface/ Water Coliform, E. Coli,

Parasites
DRY INGREDIENTS
Barley malt Micro (fecal

contamination from birds,
mice)
Wheat (malted/ non-malted), Micro (fecal

contamination from birds,
mice)
Cereal Grain, e.g. corn, oats, Micro (fecal

rice contamination from birds,
mice)
Hops Fecal contamination

(E. coli)
OTHER INGREDIENTS
Yeast Cross contaminated e.g.

Salmonella
Carbohydrate Matter Clostridium

(e.g. sucrose, syrup,
honey)

HACCP Plan - Form 5
OTHER INGREDIENTS (Continued)
Yeast Cross contaminated e.g.

Salmonella
Carbohydrate Matter Clostridium

(e.g. sucrose, syrup,
honey)
Salt None identified
Hop Oil None identified
Hop Extract None identified
Nitrogen/ Oxygen/ None Identified

Compressed Air
Purchased CO2
Regenerated CO2 None identified
Liquid Wheat Extract None identified
Caramel None identified
Dextrin None Identified
Food Enzymes None identified
Stabilizing Agents None identified
Water preparation agents None identified
Preservatives None Identified
Yeast Foods None Identified
Processing aids Fecal contamination (e.g.

Examples Gelatin, Irish Gelatin, Irish Moss)
Moss, Wood Shavings
PRIMARY PACKAGING MATERIAL
New glass None identified
Used glass Bacteria
Lined aluminum cans and None identified

bottles

HACCP Plan - Form 5
New Kegs None identified
PRIMARY PACKAGING MATERIAL (Continued)
Used Kegs None identified
Plastic Bottles, e.g. PET None Identified
Crowns None identified
Closures & Can Ends None Identified
PROCESS STEPS
PS1- RECEIVING Micro contamination from

receiving open containers
(e.g. bird droppings).
PS2- STORAGE/ HANDLING Mold growth from

improper storage
conditions
Insect or pest infestation
PS3 - BREWING
B1 - Receiving (See PS1 above)
B2 - Storage (See PS2 above)
B3 - Milling None identified
B4 - Cereal Cooker None identified
B5 - Mashing (Mash Mixer, None identified

Mash Cooker)
B6 - Lautering (Lauter Tun, None identified

Mash Filter removal of spent
grains
B7 Holding Tank None identified
B8 - Kettle None identified
B9 Whirlpool None identified
B10 - Wort Cooling (Heat None identified

Exchanger)
PS4 -FERMENTATION

HACCP Plan - Form 5
Cold Wort (from B10) None identified
PROCESS STEPS (Continued)
F1 Wort Oxygenation/ Wort None identified

Aeration
F2 - Fermentation None identified
F3 - Cooling None identified
F4 - Green Beer None identified
PS4 SUB-PROCESS YEAST

PREPARATION
Y1 Propagation None identified
Y2 Storage None identified
Y3 Acid Washing None identified
PS5 - AGING/ CLARIFICATION/

FILTRATION
A1 - Cooling None identified
A2 - Buffer tank None identified
A3 - Centrifuge None identified
A5 - Cooling tank None identified
A6 - Aging Tank None identified
A7 - Secondary Storage None identified
A8 - Surge/ buffer Tank None identified
A9 Filtration None identified
A10 Bright Beer Storage (See PS6 below)
PS6 BRIGHT BEER STORAGE None identified
PS7 BRIGHT BEER PROCESSING
PS7 (SF) Sterile Filtration

HACCP Plan - Form 5
SF1 - Bright Beer Tank None identified
SF2 - Filtration None identified
SF3 - Sterile Beer Tank None identified
PS7(FP) Flash Pasteurization
FP1 - Bright Beer Tank None identified
FP2 - Pasteurization None identified
FP3 - Pasteurized Beer Tank None identified
PS8 RB
RETURNED BOTTLES PREP
(FLOAT GLASSWARE PREP)
RB1 - Receiving/ Storage None identified
RB2 - De-palletizing None identified
RB3- RB4 - De-casing & None identified

Inspection (visual)
RB5 - Bottle Wash Loading None identified
RB6 - Pre-rinse sprays None identified
RB7 - Soak Tanks With Caustic None identified
RB8 - Hydro Jet Sprays Spray malfunction and

debris is left in bottle (e.g.
pathogenic Clostridium,
Listeria, Hepatitis (A/B/C)
RB9- Post-Soak None identified
RB10 - External Flush None identified
RB11 - Ext. Rinse None identified
RB12 - Interior Rinse None identified
RB13 - Final Rinse None identified
PS8 NB -
NEW BOTTLES (GLASSWARE)
PREP
NB1- NB2 - Receiving & None identified


HACCP Plan - Form 5
NB3 NB 6 Storage (Pallet None identified

Prep, De-palletize)
NB7 Inspection (Human, None identified

visual)
NB8 - Bottle Loading, None identified
NB9 - Bulk Glass Rinser None identified
PS8 BT - BOTTLING
BT1 None identified

(Human or Machine inspection)
BT2 Down Bottle Filler In-Feed None identified

Control
BT3 BT5 Filling (Purges , None identified

Filling, Fobbing)
BT6 - Crowning None identified
BT7 BT 8 Bottle Flush (Full None identified

Bottle Wash - external)
BT9 None identified

Pasteurize
BT10 - Foam Inspection &/or None identified

Candling
BT11 Drying (Bottle Drying None identified

and Air Knives)
BT12 BT13 Labelling, Coding None identified
BT14 Filled Bottle Inspection None identified
BT15 BT18 Packing & Sealing None identified

(Divert to packers, Carton, Case
Pack, Sealing)
BT19 BT20 Secondary Code & None identified

Inspection (Secondary
Packaging, Code/Inspection)

HACCP Plan - Form 5
BT21 None identified

Palletize
BT22 - Storage (or Live Load) None identified
BT23 - Shipping None identified
PS8 (K) - KEGGING
K1 - Receiving (See PS1) None identified
K2 K3 Storage & Handling , None identified

De-palletizing (See PS2)
K4 - External Inspection None identified
K5 K6 External Cleaning (Ext None identified

Wash/Inspection)
K7 None identified
Racking
K8 K12 Internal Cleaning None identified

(Purge, Flush, Wash, Purge,
Rinse)
K13 - Sterilize & Hold None identified
K14 K 15 Purge to Empty & None identified

Counter pressure
K 16 - K17 Barnes Neck Sanitize None identified

& Inspect
K18 - Filling None identified
K19 K 21 Barnes Neck, Wash None identified

& Sanitize
K22 - Dust Cap None identified
K23 - Air Dry None identified
K24 - Product Code Applied None identified
K25 K 26 Weigh (In-line None identified

weighing) & Palletize

HACCP Plan - Form 5
K27 - Storage None identified
K28 - Shipping None identified
PS8 (C) - CANNING
C1 - Receiving None identified
C2 - Storage & Handling Bacterial contamination

from leaking roof or pipes
C3 C 4 De-palletize / Pallet ID None identified

(Collect & Timestamp Can Pallet
ID, De-palletize)
C5 - Online visual inspection None identified
C6 - Primary code applied None identified
C7 - Bulk in-line rinser None identified
C8 C 10 Filling (pre- None identified

evacuation & beer fill)
C11 C13 Seaming None identified
C14 - External Can Flush None identified
C15 None identified

Pasteurizer
C16 C17 Drying None identified
C18 - Fill Height Inspection None identified
C19 - Divert to Packers None identified
C20 - Hi-Cone Machine None identified
C21 - Case Packers None identified
C22 Inspection (Human, None identified

visual) Inspection
C23 C24 Tray Machine & None identified

Code

HACCP Plan - Form 5
C25 None identified

Palletize
C26 - Storage (or Live Load) None identified
C27 None identified

Shipping
PS8 T -
TANKERING
T1 - Empty Tanker (Receiving) None identified
T2 - Tanker Washing/ Rinsing None identified
T3 - Tanker Purging None identified
T4 - Tanker Filling/ Loading Insect or pest infestation

of hoses
T5 Tanker Shipping None identified
T6 T7 Full Tanker Receiving & Insect or pest infestation

Unloading of hoses

HACCP Plan - Form 5
Date: Approved by:

FORM 6:
CHEMICAL HAZARDS

HACCP Plan - Form 6
Title: Form 6 Hazard Identification - Chemical Hazards

List all chemical hazards related Identified chemical hazards Controlled at:
to ingredients, incoming
material, processing, product
flow, etc.
INGREDIENTS
LIQUID INGREDIENTS
City Water Pesticides, Heavy metals
Purchased Water Cleaning chemicals, cross

contamination from previous
load
Well/ Lake/ Surface/ Water Pesticides, Heavy metals
DRY INGREDIENTS
Barley malt Pesticides, Mycotoxins,

Allergen (cross-contamination
from carrier), NDMA
Wheat (malted/ non-malted), Pesticides, Mycotoxins,

Allergen, NDMA
Cereal Grain, e.g. corn, oats, Pesticides, Mycotoxins,

rice Allergen (cross-contamination
from carrier), NDMA
Hops Pesticides, Mycotoxins
OTHER INGREDIENTS
Yeast Heavy Metals, cleaning

chemicals (used in tankers)
Carbohydrate Matter Antibiotic residue, heavy

(e.g. sucrose, syrup, metal (honey)
honey)
Salt Non-food grade
Hop Oil Residual solvents, Non-food

grade

HACCP Plan - Form 6
Hop Extract Residual solvents, Non-food

grade
Nitrogen/ Oxygen/ Chemical non-volatile gases,

Compressed Air Non-food grade
Purchased CO2
Regenerated CO2 Contamination from oil (from

the compressor)
Liquid Wheat Extract Allergen
Caramel Non-food grade
Dextrin Non-food grade
Food Enzymes Non-food grade
Stabilizing Agents Heavy metals, Non-food

grade
Water preparation agents Heavy metals, Non-food

grade
Preservatives Allergens (Sulphites), Non-

food grade
Yeast Foods Heavy metals, Non-food

grade
Processing aids Heavy metals, Non-food

Examples Gelatin, Irish grade
Moss, Wood Shavings
Used glass Lubricants, mycotoxins

bottles

HACCP Plan - Form 6
Plastic Bottles, e.g. PET None identified
Closures & Can Ends None identified
PROCESS STEPS
PS1- RECEIVING Chemical Contamination
from truck (damage, leaks,
odors)
PS2- STORAGE/ HANDLING Chemical - Cross-

contamination from allergens
(e.g. wheat)
PS3 - BREWING
B3 - Milling Chemical Allergen cross-

contamination (e.g. from
residues in the mill)

Mash Cooker)

grains

Exchanger)
PS4 -FERMENTATION

Aeration

HACCP Plan - Form 6
F3 - Cooling Coolant leak

PREPARATION

FILTRATION
A1 - Cooling Coolant leak
A5 - Cooling tank Coolant leak
A6 - Aging Tank Coolant leak
A7 - Secondary Storage Coolant leak

Sulphites as an allergen
A8 - Surge/ buffer Tank Sulphites as an allergen
A9 Filtration Sulphites as an allergen
PS6 BRIGHT BEER STORAGE Coolant leak

Cleaning chemicals
PS7 BRIGHT BEER

PROCESSING
SF1 - Bright Beer Tank Coolant leak

Cleaning chemicals

HACCP Plan - Form 6
SF2 - Filtration Sulphites as an allergen
FP1 - Bright Beer Tank Coolant leak

Cleaning chemicals
FP2 - Pasteurization Contamination from coolant
PS8 RB

Inspection (visual)
RB7 - Soak Tanks With Too concentrated, too low, no

Caustic caustic, wrong chemical
Bottle unable to drain
RB8 - Hydro Jet Sprays Bottle unable to drain
RB9- Post-Soak Bottle unable to drain
RB12 - Interior Rinse Spray malfunction

Bottle plugged unable to drain
RB13 - Final Rinse Bottle unable to drain
PS8 NB -
PREP

HACCP Plan - Form 6


Prep, De-palletize)

visual)
NB9 - Bulk Glass Rinser Contaminated air, sanitizing

spray
PS8 BT - BOTTLING
BT1 MACHINE:
Empty Bottle Inspection Failure of the system to detect
(Human or Machine residual liquid and caustic
inspection)
HUMAN:
Failure of personnel to detect
residual liquid
BT2 Down Bottle Filler In- None identified

Feed Control
BT3 BT5 Filling (Purges , CIP chemicals in bottle

Filling, Fobbing)
BT6 - Crowning Lubricants

BT9 None identified

Pasteurize
BT10 - Foam Inspection &/ or None identified

Candling

and Air Knives)
BT12 BT13 Labelling, Product not coded or not

Coding correctly coded

HACCP Plan - Form 6
BT15 BT18 Packing & None identified

Sealing
(Divert to packers, Carton,
Case Pack, Sealing)
BT19 BT20 Secondary Code Product not coded or not

& Inspection (Secondary correctly coded

Palletize
PS8 (K) - KEGGING

K5 K6 External Cleaning Old codes not effectively

(Ext Wash/Inspection) removed
K7 None identified
Racking
K8 K12 Internal Cleaning Automated

(Purge, Flush, Wash, Purge, Cleaning solution not
Rinse) effectively removed.
Manual
Cleaning solution not
effectively removed.

Counter pressure
K 16 - K17 Barnes Neck None identified

Sanitize & Inspect
K18 - Filling CIP solution

HACCP Plan - Form 6
K19 K 21 Barnes Neck, None identified

Wash & Sanitize
K24 - Product Code Applied Incorrect or missing code

PS8 (C) - CANNING
C2 - Storage & Handling Contamination from leaking

roof or pipes
C3 C 4 De-palletize / Pallet Incorrect or missing code on

ID pallet
(Collect & Timestamp Can
Pallet ID, De-palletize)
C6 - Primary code applied Incorrect or missing code
C7 - Bulk in-line rinser Chemicals from compressed

air or water

C11 C13 Seaming Chemicals, Lubricants
C15 None identified

Pasteurizer

HACCP Plan - Form 6

visual) Inspection
C23 C24 Tray Machine & Incorrect or missing code

Code
C25 None identified

Palletize
C27 None identified

Shipping
PS8 T -
TANKERING
T1 - Empty Tanker (Receiving) Cleaning chemicals and/ or

sanitizer
T2 - Tanker Washing/ Rinsing Cleaning chemicals and/ or

sanitizer
T3 - Tanker Purging Contaminated CO2
T4 - Tanker Filling/ Loading Cross contamination from

using hose on non-food
material
T6 T7 Full Tanker Receiving Cross contamination with

& Unloading chemicals from the supplier
Cross contamination from

material
Date: Approved by:

FORM 7:
PHYSICAL HAZARDS

Title: Form 7 Hazard Identification - Physical Hazards
List all physical Identified physical Controlled at:

hazards related to hazards
ingredients, incoming
material, processing,
product flow, etc.
INGREDIENTS
LIQUID INGREDIENTS
City Water Silt
Purchased Water None identified
Well/ Lake/ Surface/ Water Silt
DRY INGREDIENTS
Barley malt Glass, Metal
Wheat (malted/ non- Glass, Metal

malted),
Cereal Grain, e.g. corn, Glass, Metal

oats, rice
Hops Insects, metal
OTHER INGREDIENTS
Yeast None identified
Carbohydrate Matter None identified

(e.g. sucrose,
syrup, honey)
Salt Rocks
Hop Oil Plastic
Hop Extract Plastic
Nitrogen/ Oxygen/ None identified

Compressed Air
Purchased CO2

Liquid Wheat Extract Plastic (from packaging)
Caramel Plastic (from container)
Dextrin Plastic (from container)
Preservatives None identified
Yeast Foods None identified
Processing aids None identified

Examples Gelatin, Irish
Moss, Wood Shavings
New glass Critical Glass Defects , Glass
Used glass Critical Glass Defects , Dirt,

Dust, Glass, Syringes, Medical
Patches
Lined aluminum cans Metal Shavings

and bottles
New Kegs Metal Shavings
PROCESS STEPS
PS1- RECEIVING Pests in hoses used for

transferring material, Bulk
Receiving

PS2- STORAGE/ HANDLING Insect or pest infestation
PS3 - BREWING

Mash Cooker)

Mash Filter removal of
spent grains

Exchanger)
PS4 -FERMENTATION

Aeration
F3 - Cooling
PS4 SUB-PROCESS
YEAST PREPARATION

PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
A10 Bright Beer Storage None identified
PS6 BRIGHT BEER None identified

STORAGE
PS7 BRIGHT BEER

PROCESSING
PS7 (SF) Sterile

Filtration
PS7(FP) Flash
Pasteurization

PS8 RB
RB1 - Receiving/ Storage Damage to bottles
RB2 - De-palletizing Damage to bottles
RB3- RB4 - De-casing & Damage to bottles

Inspection (visual)
RB5 - Bottle Wash Loading Damage to bottles
RB6 - Pre-rinse sprays Damage to bottles (e.g.

Temperature shock due to
storage)
RB7 - Soak Tanks With Damage to bottles

Caustic
RB8 - Hydro Jet Sprays Damage to bottles
Bottle contains foreign object

(spray malfunction)

(plugged but sprays cannot clear
object)
RB9- Post-Soak Damage to bottles (e.g.

Temperature shock)
Bottle plugged
RB10 - External Flush Damage to bottles (e.g.

Temperature shock)
RB11 - Ext. Rinse Damage to bottles

(e.g. Temperature shock)
RB12 - Interior Rinse Damage to bottles

(spray malfunction)

object)

RB13 - Final Rinse Damage to bottles

(spray malfunction)

object)
PS8 NB -
NEW BOTTLES
(GLASSWARE) PREP
NB1- NB2 - Receiving & Damage to bottles

NB3 NB 6 Storage (Pallet Damage to bottles

Prep, De-palletize)
NB7 Inspection (Human, Missed critical glass defects

visual)
NB8 - Bottle Loading, Damage to bottles
NB9 - Bulk Glass Rinser Spray malfunction

(e.g. plugged sprays)
PS8 BT - BOTTLING
BT1 MACHINE:
Empty Bottle Inspection Failure of the system to detect
(Human or Machine foreign matter, glass defects,
inspection) bottle damage
HUMAN:
Failure of personnel to detect
foreign matter, glass defects,
glass damage
BT2 Down Bottle Filler In- Glass inclusions from breakage

Feed Control of down bottle at filler in-feed
BT3 BT5 Filling (Purges , Chipping of bottles (e.g. from

Filling, Fobbing) filling equipment), glass
inclusion
Auto-Flush
Burst bottle leading to glass
inclusion
Manual Flush
Burst bottle leading to glass
inclusion

BT6 - Crowning Bottle finish damage

(leading to glass inclusions)
BT7 BT 8 Bottle Flush None identified

(Full Bottle Wash - external)
BT9 None identified

Pasteurize
BT10 - Foam Inspection HUMAN:

&/or Candling Physical Failure to detect
foreign matter (including glass)
MACHINE:
Physical Failure to detect
foreign matter (including glass)
BT11 Drying (Bottle None identified

Drying and Air Knives)
BT12 BT13 Labelling, Product not coded or not

BT14 Filled Bottle None identified

Inspection

Sealing

Case Pack, Sealing)
BT19 BT20 Secondary Product not coded, or not

Code & Inspection correctly coded
(Secondary Packaging,
Code/Inspection)

Palletize
BT22 - Storage (or Live None identified

Load)
PS8 (K) - KEGGING

K2 K3 Storage & Handling None identified

, De-palletizing (See PS2)
K5 K6 External Cleaning Old codes not effectively

(Ext Wash/Inspection) removed
K7 None identified
Racking

(Purge, Flush, Wash,
Purge, Rinse)
K14 K 15 Purge to Empty None identified

& Counter pressure

Sanitize & Inspect

Wash & Sanitize
K24 - Product Code Applied Incorrect or missing code

PS8 (C) - CANNING
C2 - Storage & Handling None identified

C3 C 4 De-palletize / Incorrect or missing code on

Pallet ID pallet
(Collect & Timestamp Can
C5 - Online visual None identified

inspection
C6 Primary code applied Incorrect or missing code

C15 None identified

Pasteurizer

visual) Inspection
C23 C24 Tray Machine & Incorrect or missing code

Code
C25 None identified

Palletize
C26 - Storage (or Live None identified

Load)
C27 None identified

Shipping

PS8 T -
TANKERING
T1 - Empty Tanker None identified

(Receiving)
T2 - Tanker Washing/ None identified

Rinsing
T4 - Tanker Filling/ Loading None identified
T6 T7 Full Tanker None identified

Receiving & Unloading
Date: Approved by:

FORM 8:
CRITICAL CONTROL
POINTS

Critical Control Points - Form 8
Title: Form 8 Critical Control Points

Incoming Category Determine if fully controlled by Q1. Could a Q2. Is it Q3. Is this Q4. Will a CCP
material/ process and Pre-requisite program. control likely that process subsequen Number
step/ hazards on identified measure(s) contaminati step t step
schematic hazard. *If yes = indicate Pre-requisite be used by on with the specificall eliminate + proceed
diagram Program and proceed to next the operator identified y the to next
identified hazard. at any hazard designed identified identified
process could to hazard or hazard
*If no = proceed to question1 (Q1). step? occur in eliminate/ reduce
excess of reduce likely
If NO = not a the the likely occurrenc
CCP + acceptable occurrenc e to an
identification level or e of the acceptable
on how this could identified level?
hazard will be increase to hazard to
controlled an an If NO = CCP + go to last
before and unacceptab acceptabl column
after the le level? e level?
process If YES =
If NO = not If NO = not a CCP
+ proceed to a CCP + next + identify
the next proceed to question subsequent
identified the next (Q4) step +
hazard identified proceed to
hazard If YES = the next
If YES = CCP + go identified
description + If YES = to last hazard
next question next column
(Q2) question
(Q3)

INGREDIENTS
LIQUID INGREDIENTS
WATER
City Water Biological - PP Premises, Water Quality (BAC

Coliform, E. A4.1) All Hazards
Coli
Chemical -
Pesticides,
Heavy metals
Physical
Silt
Purchased Water Biological - PP Premises, Water Quality

Coliform, E. (BAC A4.1)
Coli
PP - Transportation Receiving &
Chemical Storage (BAC B1.1)
Cleaning
chemicals, - COA/ Supplier Audits
cross
contamination
from previous
load
Well/ Lake/ Biological - PP Premises, Water Quality

Surface/ Water Coliform, E. (BAC A4.1)
Coli, Parasites
Chemical -
Pesticides,
Heavy metals
Physical
Silt

DRY INGREDIENTS
Barley malt Biological PP - Transportation Receiving &

Micro (faecal Storage (BAC B1.1)
contamination
from birds, - COA from supplier
mice)
Pesticides,
Mycotoxins, - COA / Letter of Guarantee
Allergen
(cross- PP - Transportation Receiving &
contamination Storage (BAC B1.1) - Receiving
from carrier), Inspection (screens, magnets)
NDMA
Physical
Glass, Metal

Wheat (malted/ Biological PP - Transportation Receiving &

non- Micro (faecal Storage (BAC B1.1)
malt contamination
ed), from birds, + COA from supplier
mice)
Pesticides,
Mycotoxins, + COA / Letter of Guarantee,
Allergen,
NDMA Allergen Management Program
Physical PP - Transportation Receiving &

Glass, Metal Storage (BAC B1.1)
+ Receiving Inspection (screens,

magnets)
Cereal Grain, Biological PP - Transportation Receiving &

e.g. Micro (faecal Storage (BAC B1.1)
corn contamination
, from birds, + COA from supplier
oats, mice)
rice PP - Transportation Receiving &
Pesticides,
Mycotoxins, + COA / Letter of Guarantee,
Allergen
(cross- Allergen Management Program
contamination
from carrier), PP - Transportation Receiving &
NDMA Storage (BAC B1.1)
Physical + Receiving Inspection (screens,

Glass, Metal magnets)

Hops Biological PP - Transportation Receiving &

Faecal Storage (BAC B1.1)
contamination
(E. coli) + COA
Chemical PP Transportation, Receiving &

Pesticides, Storage (BAC B1.1)
Mycotoxins
+ COA
Physical
Insects, metal PP - Transportation Receiving &
Storage (BAC B1.1)
+ COA, Inspection
OTHER INGREDIENTS
Yeast Biological
Cross
contaminated
e.g.
Salmonella

Heavy Metals, Storage (BAC B1.1)
cleaning
chemicals + COA
(used in
tankers)
Physical PP Transportation, Receiving &

None Storage (BAC B1.1)
identified
+ COA, Wash Tickets

Carbohydrate Biological
Matt Clostridium
er
(e.g. sucrose, Antibiotic Storage (BAC B1.1)
syru residue,
p, heavy metal + COA
hone (honey)
y)
identified
+ COA
Salt Biological Yes No

None Screens,
identified filters,
inspection
Non-food Storage (BAC B1.1)
grade
+ COA
(Partially Controlled)

Rocks Storage (BAC B1.1)
+ Inspection

Hop Oil Biological

None
identified
Chemical + PP Transportation, Receiving &

Residual Storage (BAC B1.1)
solvents, Non-
food grade COA

Plastic Storage (BAC B1.1)
+ COA, Inspection
Hop Extract Biological

None
identified

Residual Storage (BAC B1.1)
solvents, Non-
food grade + COA

Plastic Storage (BAC B1.1)
+ COA, Inspection

Nitrogen/ Biological
Oxygen/ None
Compressed Air Identified
Purchased CO2 Chemical PP Transportation, Receiving &

Chemical non- Storage (BAC B1.1)
volatile gases,
Non-food + COA, QC Testing
grade
Physical
None
identified
Regenerated Chemical - PP - Equipment (BAC C1.2)

CO2 Contamination
from oil (from
the
compressor)

Liquid Wheat Biological

Extract None
identified
Chemical Allergen Management Program

Allergen

Plastic (from Storage (BAC B1.1)
packaging)
+ COA
Caramel Biological
None
identified

grade
+ COA

container)
+ COA

Dextrin Biological
None
identified

grade
+ COA

container)
+ COA
Food Enzymes Biological

None
identified

grade
+ COA
Physical
None
identified

Stabilizing Biological
Agents None
identified

Heavy metals, Storage (BAC B1.1)
Non-food
grade + COA + COA
Physical
None
identified
Water Biological
preparation None
agents identified

Non-food
grade + COA + COA
Physical
None
identified

Preservatives Biological
None
identified

Allergens Storage (BAC B1.1)
(Sulphites),
Non-food + COA,
grade
Allergen Management Program
Physical
None
identified
Yeast Foods Biological

None
identified

Non-food
grade + COA,
Physical
None
identified

Processing aids Biological

Faecal
Examples contamination
Gelatin, Irish (e.g. Gelatin,
Moss, Wood Irish Moss)
Shavings
Non-food
grade + COA

identified
+ COA
PRIMARY PACKAGING MATERIAL Q1 Q2 Q3 Q4
New glass Biological-

None
identified
Chemical
None
identified
Physical - (Partially Controlled) Yes Bottle Yes No Yes-

Critical Glass Rinse Empty
Defects , PP Transportation, Receiving & Bottle
Glass Storage (BAC B1.1) Inspection
+COA, Inspection

Used glass Biological- Yes No (no

Bacteria Pasteurization pathogens
No known to
survive in
final product
due to
properties of
beer, e.g.
low pH,
alcohol
content see
Form 1)
Yes
Chemical (Partially Controlled)

Lubricants,
mycotoxins PP Transportation, Receiving & Yes Bottle Yes No Yes
Storage (BAC B1.1) Rinse Empty
Bottle
+ Inspection, Inspection/
RLD
Physical - No Yes Bottle
Critical Glass Wash No Yes
Defects , Dirt, Empty
Dust, Glass, Bottle
Syringes, Inspection
Medical
Patches,

Lined aluminum Biological

cans and bottles None
identified
Chemical
None
identified
Physical (Partially Controlled) Yes Rinse No
Metal PP Transportation, Receiving &

Shavings Storage (BAC B1.1)
+COA
New Kegs Biological

None
identified
Chemical
None
identified
Physical (Partially Controlled) Yes - Rinse No

Metal
Shavings Rinse

Used Kegs Biological

None
identified
Chemical
None
identified
Physical
None
identified
Plastic Bottles, Biological

e.g. PET None
identified
Chemical
None
identified
Physical
None
identified
Crowns Biological
None
identified
Chemical
None
identified
Physical
None
identified

Closures & Can Biological

Ends None
identified
Chemical
None
identified
Physical
None
identified

PROCESS STEPS
PS1- RECEIVING Biological PP Premises (BAC A1.1 & BAC

Micro A2.1)
contamination
from receiving PP - Pest Control (BAC E2.1)
open
containers (e.g.
bird droppings).

Contamination Storage (BAC B1.1)
from truck
(damage,
leaks, odors)
Physical
Pests in hoses PP Transportation, Receiving &
used for Storage (BAC B1.1)
transferring
material, Bulk + Seal Integrity
Receiving
PP - Pest Control (BAC E2.1)
PP Personnel (BAC D1.2)
+ Training

PS2- STORAGE/ Biological - PP - Premises (BAC A2.1)

HANDLING Mold growth
from improper PP - Sanitation (BAC E1.1)
storage
conditions
Chemical - Allergen Management Program

Cross-
contamination
from allergens
(e.g. wheat)
Physical & PP - Pest Control (BAC E2.1)

Biological -
Insect or pest
infestation
PS3 - BREWING
B1 - Receiving (See PS1

above)
B2 - Storage (See PS2

above)
B3 - Milling Chemical PP - Sanitation (BAC E1.1)

Allergen cross-
contamination Allergen Management Program
(e.g. from
residues in the
mill)
B4 - Cereal None identified

Cooker

B5 - Mashing None identified

(Mash Mixer,
Mash Cooker)
B6 - Lautering None identified

(Lauter Tun, Mash
Filter removal of
spent grains
B10 - Wort None identified

Cooling (Heat
Exchanger)
PS4
-FERMENTATION
Cold Wort (from None identified

B10)
F1 Wort None identified

Oxygenation/
Wort Aeration
F3 - Cooling Chemical - PP Equipment (BAC C1.2)

Coolant leak

PS4 SUB-
PROCESS
YEAST
PREPARATION
Y3 Acid None identified

Washing
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling Chemical - PP Equipment (BAC C1.2)

Coolant leak
A5 - Cooling tank Chemical - PP Equipment (BAC C1.2)

Coolant leak
A6 - Aging Tank Chemical - PP Equipment (BAC C1.2)

Coolant leak

A7 - Secondary Chemical - PP Equipment (BAC C1.2)

Storage Coolant leak
Sulphites as an Allergen Management Program

allergen
A8 - Surge/ buffer Chemical - Allergen Management Program

Tank Sulphites as an
allergen
A9 Filtration Chemical - Allergen Management Program

Sulphites as an
allergen
A10 Bright Beer (See PS6

Storage below)
PS6 BRIGHT Chemical PP Equipment (BAC C1.2)

BEER STORAGE
Coolant leak Allergen Management Program
Sulphites as an PP - Sanitation (BAC E1.1)

allergen
Cleaning
chemicals
PS7 BRIGHT
BEER
PROCESSING
PS7 (SF)
Sterile Filtration

SF1 - Bright Beer Chemical

Tank
Coolant leak PP Equipment (BAC C1.2)

allergen
Cleaning PP - Sanitation (BAC E1.1)

chemicals
SF2 - Filtration Sulphites as an Allergen Management Program

allergen
SF3 - Sterile Beer None identified

Tank
PS7(FP) Flash
Pasteurization
FP1 - Bright Beer Chemical PP Equipment (BAC C1.2)

Tank
Coolant leak

allergen
Cleaning PP - Sanitation (BAC E1.1)

chemicals

FP2 - Chemical PP Equipment (BAC C1.2)

Pasteurization
Contamination
from coolant
FP3 - Pasteurized None identified

Beer Tank
PS8 RB
RETURNED
BOTTLES PREP
(FLOAT
GLASSWARE
PREP)
RB1 - Receiving/ Physical - PP Transportation, Receiving &

Storage Damage to Storage (BAC B1.1)
bottles
Training
RB2 - De- Physical - PP Equipment (BAC C1.2)

palletizing Damage to
bottles PP Transportation, Receiving &
Storage (BAC B1.1)
Training

RB3- RB4 - De- Physical - PP Equipment (BAC C1.2)

casing & Damage to
Inspection (visual) bottles PP Personnel (BAC D1.2)
Training
RB5 - Bottle Physical - PP Equipment (BAC C1.2)

Wash Loading Damage to
bottles PP Personnel (BAC D1.2)
Training
RB6 - Pre-rinse Physical - PP Equipment (BAC C1.2)

sprays Damage to
bottles (e.g. PP Transportation, Receiving &
Temperature Storage (BAC B1.1)
shock due to
storage)
RB7 - Soak Tanks Physical - PP Equipment (BAC C1.2)

With Caustic Damage to
bottles
Chemical PP Equipment (BAC C1.2)

Too
concentrated, PP Transportation, Receiving &
too low, no Storage (BAC B1.1)
caustic, wrong
chemical PP Personnel (BAC D1.2)
Chemical - Training
Bottle unable to
drain No Yes (EBI/ Yes No Yes(EBI/
RLD) RLD)

RB8 - Hydro Jet Biological (Partially Controlled) Yes (no No

Sprays Spray pathogens
malfunction PP Equipment (BAC C1.2) known to
and debris is survive in final
left in bottle product
(e.g. properties of
pathogenic beer, e.g. low
Clostridium, pH, alcohol
Listeria, content see
Hepatitis Form 1)
(A/B/C)
Physical -
Damage to Yes (EBI)
bottles,
Physical - (Partially Controlled)

Bottle contains
foreign object PP Equipment (BAC C1.2) Yes No Yes (EBI)
(spray
malfunction)
Physical
Bottle contains Yes (EBI)
foreign object PP Equipment (BAC C1.2)
(plugged but
sprays cannot
clear object) Yes (EBI/
No RLD) Yes No Yes (EBI)
Chemical
Bottle unable to
drain
No Yes No Yes (EBI/

RLD)

RB9- Post-Soak Physical - (Partially Controlled) Yes (EBI) Yes No Yes (EBI)
Damage to
bottles (e.g. PP Equipment (BAC C1.2)
Temperature
shock), PP Personnel (BAC D1.2)
Training
Physical - Yes (EBI) Yes No Yes (EBI)
Bottle plugged
Chemical No
Bottle unable to Yes (EBI/ Yes No Yes (EBI/
drain RLD) RLD)
No
RB10 - External Physical - (Partially Controlled) Yes (EBI) Yes No Yes (EBI)
Flush Damage to
bottles (e.g. PP Equipment (BAC C1.2)
Temperature
shock) PP Personnel (BAC D1.2)
Training
RB11 - Ext. Rinse Physical - (Partially Controlled) Yes (EBI) Yes No Yes (EBI)
Damage to
bottles PP Equipment (BAC C1.2)
(e.g.
Temperature PP Personnel (BAC D1.2)
shock) Training

RB12 - Interior Physical - (Partially Controlled) Yes (EBI) Yes No Yes (EBI)
Rinse Damage to
bottles PP Equipment (BAC C1.2)
Physical -
Bottle contains
foreign object
(spray
malfunction)
Physical PP Equipment (BAC C1.2)

Bottle contains
foreign object
(plugged but
sprays cannot
clear object)
Chemical
Spray No Yes (EBI) Yes No Yes (EBI)
malfunction
PP Equipment (BAC C1.2) Yes (EBI/ Yes No Yes (EBI/
Chemical - RLD) RLD)
Bottle plugged
unable to drain
No

RB13 - Final Physical - (Partially Controlled) Yes (EBI) Yes No Yes (EBI)
Rinse Damage to
bottles, PP Equipment (BAC C1.2)
Physical -
Bottle contains
foreign object PP Equipment (BAC C1.2)
(spray
malfunction)
Physical
Bottle contains
foreign object
(plugged but
sprays cannot No Yes (EBI) Yes No Yes (EBI)
clear object)
Chemical
Bottle unable to
drain
No Yes (EBI/ Yes No Yes (EBI/
RLD) RLD)
PS8 NB -
NEW BOTTLES
(GLASSWARE)
PREP
NB1- NB2 - Physical - PP Transportation, Receiving &

Receiving & Damage to Storage (BAC B1.1)
Preliminary bottles
Inspection PP Personnel (BAC D1.2)
Training

NB3 NB 6 Physical - PP Equipment (BAC C1.2)

Storage (Pallet Damage to
Prep, De- bottles PP Personnel (BAC D1.2)
palletize) Training
NB7 Inspection Physical (Partially Controlled) Yes (EBI) Yes No Yes (EBI)
(Human, visual) Missed critical
glass defects PP Personnel (BAC D1.2)
Training
NB8 - Bottle Physical PP Equipment (BAC C1.2)

Loading, Damage to
bottles PP Personnel (BAC D1.2)
Training
NB9 - Bulk Glass Physical PP Equipment (BAC C1.2)

Rinser
Spray
malfunction
(e.g. plugged
sprays)
Chemical PP Equipment (BAC C1.2)

Contaminated
air, sanitizing PP Personnel (BAC D1.2)
spray Training
PS8 BT -
BOTTLING

BT1 MACHINE: MACHINE:
Empty Bottle Physical - (Partially Controlled) Yes (EBI) Yes Yes CCP1-P
Inspection Failure of the
system to PP Equipment (BAC C1.2)
Human or detect foreign
Machine matter, glass PP Personnel (BAC D1.2)
inspection (EBI/ defects, bottle Training
RLD) damage
Chemical -
Failure of the
system to
detect residual
liquid and
caustic
Yes (EBI/ Yes Yes CCP1-C
HUMAN: (Partially Controlled) RLD)
Physical -
Failure of PP Equipment (BAC C1.2)
personnel to
detect foreign PP Personnel (BAC D1.2)
matter, glass Training
defects, glass
damage HUMAN:
(Partially Controlled) Yes (EBI) Yes Yes CCP1-P
Chemical -
Failure of PP Personnel (BAC D1.2)
personnel to Training, SOP (personnel rotation)
detect residual
liquid (Partially Controlled)
Yes (EBI Yes Yes CCP1-C
Training
, SOP (personnel rotation)

BT2 Down Physical PP Equipment (BAC C1.2)

Bottle Filler In- Glass
Feed Control inclusions from PP Personnel (BAC D1.2)
breakage of
down bottle at
filler in-feed

BT3 BT5 Filling Physical PP Equipment (BAC C1.2)

(Purges , Filling, Chipping of
Fobbing) bottles (e.g. PP Personnel (BAC D1.2)
from filling Training
equipment),
glass inclusion
Auto-Flush: Yes (SOP

Burst Bottle
Physical Detection
Burst bottle System/ Filler
leading to glass Flush/ Auto Yes Yes CCP2-P
inclusion Auto-Flush: Flush)
PP Equipment (BAC C1.2)

Training
Manual Flush: Yes (SOP on
PP Transportation, Receiving & Burst Bottle
Physical Storage (BAC B1.1) Monitoring
Burst bottle and Reject &
leading to glass Flush)
inclusion
Manual Flush:

BT3 BT5 Filling (Partially Controlled) Yes No Yes

(Purges , Filling, (Foam
Fobbing) PP Equipment (BAC C1.2) Inspectio
(Continued) n&/or
PP Personnel (BAC D1.2) Candling)
Training
Chemical
CIP chemicals PP Transportation, Receiving &
in bottle Storage (BAC B1.1)
PP - Sanitation (BAC E1.1)

Training
BT6 - Crowning Physical (Partially Controlled) Yes (SOP, Yes No Yes

Bottle finish Foam (Foam
damage PP Equipment (BAC C1.2) Inspection Inspectio
(leading to &/or Candling) n &/or
glass PP Personnel (BAC D1.2) Candling)
inclusions) Training
Chemical
Lubricants

BT7 BT 8 Bottle None identified

Flush (Full Bottle
Wash - external)
BT9 None identified

Pasteurize
BT10 - Foam Physical

Inspection &/or Failure to
Candling (Human) detect foreign PP Personnel (BAC D1.2) Yes (increase No
matter Training number of
Note: Automated (including inspectors)
Foam Inspection glass)
is not within the
scope of this
generic model.
BT11 Drying None identified

(Bottle Drying and
Air Knives)
BT12 BT13 Product not PP - Recall (BAC F1.2)

Labelling, Coding coded or not
correctly coded PP Equipment (BAC C1.2)
BT14 Filled None identified

Bottle Inspection
BT15 BT18 None identified

Packing & Sealing
(Divert to packers,
Carton, Case
Pack, Sealing)

BT19 BT20 Product not PP - Recall (BAC F1.2)

Secondary Code coded, or not
& Inspection correctly coded PP Equipment (BAC C1.2)
(Secondary
Packaging,
Code/Inspection)

Palletize
BT22 - Storage None identified

(or Live Load)
PS8 (K) -
KEGGING
K1 - Receiving None identified

(See PS1)
K2 K3 Storage None identified

& Handling , De-
palletizing (See
PS2)
K4 - External None identified

Inspection
K5 K6 External Old codes not PP - Recall (BAC F1.2)

Cleaning (Ext effectively
Wash/Inspection) removed
K7 None identified
Racking

K8 K12 Internal Automated Automated

Cleaning (Purge,
Flush, Wash, Chemical PP - Sanitation (BAC E1.1)
Purge, Rinse) Cleaning
solution not PP Equipment (BAC C1.2)
effectively
removed. PP Personnel (BAC D1.2)
Training
Manual:
Chemical
Cleaning
solution not No Yes Yes Yes CCP3-C
effectively Manual:
removed.

Training
K13 - Sterilize & None identified

Hold
K14 K 15 Purge None identified

to Empty &
Counter pressure
K 16 - K17
Barnes Neck
Sanitize & Inspect

K18 - Filling Chemical PP - Sanitation (BAC E1.1)

CIP solution
Training
K19 K 21 None identified

Barnes Neck,
Wash & Sanitize
K24 - Product Incorrect or PP - Recall (BAC F1.2)

Code Applied missing code

Training
K25 K 26 Weigh None identified

(In-line weighing)
& Palletize
PS8 (C) -
CANNING

C2 - Storage & Biological PP Premises (BAC A1.1 & BAC

Handling Bacterial A2.1)
contamination
from leaking
roof or pipes
Chemical - PP Premises (BAC A1.1 & BAC

Contamination A2.1)
from leaking
roof or pipes
C3 C 4 De- Incorrect or PP - Recall (BAC F1.2)

palletize / Pallet missing code
ID on pallet PP Personnel (BAC D1.2)
(Collect & Training
Timestamp Can
Pallet ID, De-
palletize)

inspection
C6 - Primary code Incorrect or PP - Recall (BAC F1.2)

applied missing code

Training
C7 - Bulk in-line Chemical PP Premises (BAC A4.1)

rinser Chemicals from
compressed air PP Equipment (BAC C1.2)
or water

C8 C 10 Filling None identified

(pre-evacuation &
beer fill)
C11 C13 Chemical PP Equipment (BAC C1.2)

Seaming Chemicals,
Lubricants PP Personnel (BAC D1.2)
Training
C14 - External None identified

Can Flush
C15 None identified

Pasteurizer
C18 - Fill Height None identified

Inspection
C19 - Divert to None identified

Packers
C20 - Hi-Cone None identified

Machine
C21 - Case None identified

Packers
C22 Inspection None identified

(Human, visual)
Inspection

C23 C24 Tray Incorrect or PP - Recall (BAC F1.2)

Machine & Code missing code

Training
C25 None identified

Palletize
C26 - Storage (or None identified

Live Load)
C27 None identified

Shipping
PS8 T -
TANKERING
T1 - Empty Chemical PP Transportation, Receiving &

Tanker Cleaning Storage (BAC B1.1)
(Receiving) chemicals and/
or sanitizer COA, Wash Ticket,

Training
T2 - Tanker Chemical PP Equipment (BAC C1.2)

Washing/ Rinsing Cleaning
chemicals and/ PP Personnel (BAC D1.2)
or sanitizer Training

T3 - Tanker Chemical For Regenerated CO2 PP

Purging Contaminated Equipment (BAC C1.2)
CO2
Training
For Purchased CO2 - PP

Transportation, Receiving &
Storage (BAC B1.1)
COA
T4 - Tanker Biological No Yes (no No

Filling/ Loading Insect or pest pathogens
infestation of known to
hoses survive in final
product due to
the properties
of beer, e.g.
low pH, see
Form 1)
Chemical PP Personnel (BAC D1.2)
Cross Training
contamination
from using
hose on non-
food material
T5 Tanker None identified

Shipping

T6 T7 Full Biological No Yes (no No

Tanker Receiving Insect or pest pathogens
& Unloading infestation of known to
hoses survive in final
product due to
the properties
of beer, e.g.
low pH,
alcohol
content see
Form 1)
Cross Storage (BAC B1.1)
contamination
with chemicals + COA
from the
supplier
Chemical PP Personnel (BAC D1.2)

Cross Training
contamination
from using
hose on non-
food material
Date: Approved by:


FORM 3A:

WITH CCPS


HACCP Plan - Form 3A
BAC GENERIC HACCP PLAN FORM 3a
Approved By: BAC HACCP Technical Committee

Approval Date:
Total # of Pages Including Key = 12
Page 1 of 12
KEY
Box with no fill = Process Step
Blue Filled Box = Input
Yellow Filled Box = Output
Dotted Line = Optional Step
Red Filled Circle = Last step in process
Open-ended Box = Chemical/ Material used

that is not an ingredient or processing aid
that does not contact the product directly .
CCP Critical Control Point

MASTER FLOWCHART OF
MAJOR PROCESS STEPS (PS) FOR MAKING BEER (Page 2 of 12)
RECEIVING FULL TANKER

(PS1) (Step T6)
FULL TANKER
STORAGE & HANDLING UNLOADING
(Step PS2) (Step T7)
Water & Dry

BREWING
Ingredients
(Step PS3)
MILLING/ MASHING/ LAUTERING
KETTLE/ WHIRLPOOL/ COOLING
Yeast,
Processing
Aids FERMENTATION
(Step PS4)
Processing
Aids, CO2 AGING
(Step PS5)
CLARIFICATION/ FILTERING
BRIGHT BEER STORAGE

(Step PS6)
BRIGHT BEER
Bottles, Cans, Kegs, PROCESSING
Crowns, Tankers (Step PS7)
New
Bottles
Prep PACKAGING
PS8 (NB) (Step PS8)
BOTTLING KEGGING
Returned CANNING TANKERING
Step PS8 (BT) Step PS8 (K)
Bottles Step PS8 (C) Step PS8 (T)
CCP1-C,P CCP3-C
Prep
PS8 (RB) CCP2-P
- Washing
- Rinsing - Cleaning
- Inspection
- Filling - Filling - Filling
- Filling
- Packing - Palletizing
- Flushing
WAREHOUSING/ SHIPPING
(Step PS9)

PS3 - BREWING (Page 3 of 12)
RECEIVING
(Step B1)
Storage
(Step B2)
Milling
(Step B3)
Cereal Cooker
(Step B4)
Mashing
(Step B5)
Lautering
(Step B6)
Holding Tank
(Step B7)
Kettle
(Step B8)
Whirlpool
(Step B9)
Oxygen
Wort Cooling
(Step B10)
Next Process - PS4

Fermentation

PS4 - FERMENTATION (Page 4 of 12)
COLD WORT
WORT OXYGENATION/
Oxygen/ Sterile WORT AERATION
Air (Step F1 )
Yeast Propagation
(Step Y1)
Yeast Storage
(Step Y2)
Acid Washing
(Step Y3)
FERMENTATION
YEAST
(Step F2)
CO2
Cooling
(Step F3)
Yeast
Removal
GREEN BEER
(Step F4)
Next Process - PS5 -Aging/

Clarification/ Filtration

PS5 - AGING/ CLARIFICATION/ FILTRATION (Page 5 of 12)
GREEN BEER COOLING

(Step A1)
Buffer tank
(Step A2)
Centrifuge
(Step A3)
Yeast,
By-products
Processing aids,
Stabilizers,
CO2, Preservatives Buffer tank
(Step A4)
CO2
Cooling tank
(Step A5)
CO2, Hops
Aging Tank
(Step A6) Beer,
Spent Hops, CO2
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives Secondary Storage
(Step A7) CO2, Spent
Yeast
Deaerated water,
Processing aids,
Stabilizers, CO2,
Preservatives Surge/ Buffer Tank
(Step A8)
CO2
Caramel & other
ingredients,
Processing aids,
Stabilizers, CO2,
Preservatives Filtration
(Step A9)
CO2, Spent
Yeast
Deaerated water,
CO2, Nitrogen
Bright Beer Storage
(Step A10 = PS6)
CO2
Next Process - PS7 -

Bright BeerProcessing

PS7 (BBP) - BRIGHT BEER PROCESSING (Page 6 of 12)
PS7 (SF) PS7 (P)

STERILE FILTRATION FLASH PASTEURIZATION
Bright Beer Tank Bright Beer Tank

CO2
Filtration Flash Pasteurization
Sterile Beer Tank Pasteurized Beer Tank

Next Process - PS8 -Packaging Next Process - PS8 -Packaging

Process Step 8
PS8 (RB) - RETURNED BOTTLES PREP (Page 7 of 12)
Receiving/ Storage
(Step RB1)
Caustic
De-Palletizing Hydro Jet Sprays

(Step RB2) (Step RB8)
De-Casing & Inspection

(Steps RB3-4)
Post Soak
(Step RB9)
Bottle Wash Loading

(Step RB5)
External Flush
(Step RB10)
Pre-Rinse
(Step RB6)
Water, External Rinse

Chemicals & (Step RB11)
Steam
Soak Tanks (caustic)
(Step RB7)
Water
Interior Rinse
(Steps RB12)
Water
FINAL RINSE
(Step RB13)

Process Step 8
PS8 (NB) - NEW BOTTLES PREP (Page 8 of 12)
Receiving
(Step NB1)
(Step NB2)
Storage
(Step NB3-6)
Inspection
(Step NB7)
RINSE
(Steps NB8-9)

Process Step 8
PS8 (BT) - BOTTLING (Page 9 of 12)
BOTTLES - See
Returned Bottles Prep
& New Bottle Prep Air
(Steps BT1) Drying
Water
CCP1-C, P (Step BT11)
Down Bottle Filler In-Feed Control

(Steps BT2)
Label & Code

Bright Beer, (Steps BT12-13)
CO2, Compressed Air
Filling
(Steps BT3-5)
Water CO2,
CCP2-P
Glass
Filled Bottle Inspection
(Step BT14)
Crowns, Compressed Air
Crowning
Water (Step BT6 )
Packing & Sealing

Bottle Flush (External) (Steps BT15-18)
Water (Steps BT7-8)
Steam Secondary Code & Full Case

Pasteurize
& Chemicals Inspection
(Step BT9)
(Steps BT19-20)
Foam Inspection/ Candling

(Step BT10) Palletize
(Step BT21)
Storage
(Step BT22)
Live Load
SHIPPING
(Step BT23)

Process Step 8
PS8 (K) - KEGGING (Page 10 of 12)
KEGS
Receiving
(Step K1)
Racking
(Step K7)
Filling (Step K18)
Storage, Handling,
De-palletizing Internal Cleaning
(Steps K2-3) Manual Internal Cleaning
(Steps K8-12) Automated Barnes Neck Wash &
(Steps K8-12) Sanitize
CCP3-C
(Step K19-21)
External Inspection
(Step K4 )
Sterilize & Hold Dust Cap Applied

(Step K13) (Steps K22)
External Cleaning
(Steps K5-6)
Purge to Empty &

Air Dry
Counter Pressure
(Step K23)
(Steps K14-15)
Barnes Neck Sanitize & Code

Inspect (Step K24)
(Step K16-17)
Weigh & Palletize

(Steps K25-26)
Storage
(Step K27)
Live Load
SHIPPING
(Step K28)

Process Step 8
PS8 (C) - CANNING (Page 11 of 12)
CANS
Receiving Drying (Steps C16-17)
(Step C1)
Coding
(Step C6)
Storage & Handling
Fill Height Inspection
(Step C2)
(Step C18)
Rinser
Depalletizing/ Pallet ID (Step C7)
(Steps C3-4 )
Divert to Packers
(Steps C19)
Bright
Beer, Filling
Inspection CO2 (Steps C8- 10)
(Step C5)
CO2
Hi Cone Machine
(Step C20)
Can Ends
Seaming
(Steps C11-13)
Case Packers
Water (Steps C21)
External Flush
(Step C14)
Pastuerizer Inspection
(Step C15) (Step C22)
Tray Machine & Code

(Steps C23-24)
Palletize
(Step C25)
Storage
(Step C26)
Live Load
SHIPPING
(Step C27)

Process Step 8
PS8 (T) - TANKERING (Page 12 of 12)
Empty Tanker
(Step T1)
Caustic, Water,
Acid
Tanker Washing
(Step T2)
CO2
Tanker Purge
(Step T3)
CO2
Bright Beer,
CO2
Tanker Filling
(Step T4)
Tanker Shipping
(Step T5)
Full Tanker Receiving

(Step T6)
FULL TANKER UNLOADING

(Step T7)
Date: _______________ Approved by: ________________________________

FORM 5A:
BIOLOGICAL HAZARDS
CONTROL & CCPS

Title: Form 5A Hazard Identification - Biological Hazards

BAC Generic Control & CCPs
Note No CCPs were identified for biological hazards in Beer.
List all biological hazards related Identified biological Controlled at:

to ingredients, incoming material, hazards (Bacteria,
processing, product flow, etc. parasites, viruses, etc.)
INGREDIENTS
LIQUID INGREDIENTS
City Water Coliform, E. Coli PP Premises, Water Quality

(BAC A4.1)
Purchased Water Coliform, E. Coli PP Premises, Water Quality

(BAC A4.1)
Well/ Lake/ Surface/ Water Coliform, E. Coli, PP Premises, Water Quality

Parasites (BAC A4.1)
DRY INGREDIENTS
Barley malt Micro (fecal PP - Transportation

contamination from birds, Receiving & Storage (BAC
mice) B1.1)
- COA from supplier
Wheat (malted/ non-malted), Micro (fecal PP - Transportation

contamination from birds, Receiving & Storage (BAC
mice) B1.1)
+ COA from supplier
Cereal Grain, e.g. corn, oats, Micro (fecal PP - Transportation

rice contamination from birds, Receiving & Storage (BAC
mice) B1.1)
+ COA from supplier
Hops Fecal contamination (E. PP - Transportation

coli) Receiving & Storage (BAC
B1.1)
+ COA

OTHER INGREDIENTS
Yeast Cross contaminated e.g. PP Transportation,

Salmonella Receiving & Storage (BAC
B1.1)
+ COA
Carbohydrate Matter Clostridium PP Transportation,

(e.g. sucrose, syrup, Receiving & Storage (BAC
honey) B1.1)
+ COA
Salt None identified
Hop Oil None identified + PP Transportation,

Receiving & Storage (BAC
B1.1)
+COA
Hop Extract None identified
Nitrogen/ Oxygen/ None Identified

Compressed Air
Purchased CO2
Liquid Wheat Extract None identified
Caramel None identified
Dextrin None Identified
Preservatives None Identified
Yeast Foods None Identified
Processing aids Fecal contamination (e.g. PP Transportation,

Examples Gelatin, Irish Gelatin, Irish Moss) Receiving & Storage (BAC
Moss, Wood Shavings B1.1)
+ COA

Used glass Bacteria No pathogens known to survive

in final product due to
properties of beer, e.g. low pH,
alcohol content see Form 1

bottles
Plastic Bottles, e.g. PET None Identified
Closures & Can Ends None Identified
PROCESS STEPS
PS1- RECEIVING Micro contamination from PP Premises (BAC A1.1 &

receiving open containers BAC A2.1)
(e.g. bird droppings).
PP - Pest Control (BAC E2.1)
PS2- STORAGE/ HANDLING Mold growth from PP - Premises (BAC A2.1)

improper storage
conditions PP - Sanitation (BAC E1.1)
Insect or pest infestation PP - Pest Control (BAC E2.1)
PS3 - BREWING

Mash Cooker)

grains


Exchanger)
PS4 -FERMENTATION

Aeration
F3 - Cooling None identified

PREPARATION

FILTRATION
A1 - Cooling None identified

PS6 BRIGHT BEER STORAGE None identified
PS7 BRIGHT BEER PROCESSING
PS8 RB

Inspection (visual)
RB7 - Soak Tanks With Caustic None identified
RB8 - Hydro Jet Sprays Spray malfunction and (Partially Controlled)

debris is left in bottle (e.g.
pathogenic Clostridium, PP Equipment (BAC C1.2)
Listeria, Hepatitis (A/B/C)
Also, no pathogens known to
survive in final product
alcohol content see Form 1.

RB9- Post-Soak None identified
RB12 - Interior Rinse None identified
RB13 - Final Rinse None identified
PS8 NB -
PREP


Prep, De-palletize)

visual)
NB9 - Bulk Glass Rinser None identified
PS8 BT - BOTTLING
BT1 None identified

(Human or Machine inspection)
BT2 Down Bottle Filler In-Feed None identified

Control
BT3 BT5 Filling (Purges , None identified

Filling, Fobbing)
BT6 - Crowning None identified

BT9 None identified

Pasteurize
BT10 - Foam Inspection &/or None identified

Candling


and Air Knives)
BT12 BT13 Labelling, Coding None identified
BT15 BT18 Packing & Sealing None identified

(Divert to packers, Carton, Case
Pack, Sealing)
BT19 BT20 Secondary Code & None identified

Inspection (Secondary

Palletize
PS8 (K) - KEGGING

K5 K6 External Cleaning (Ext None identified

Wash/Inspection)
K7 None identified
Racking

(Purge, Flush, Wash, Purge,
Rinse)

Counter pressure
K 16 - K17 Barnes Neck Sanitize None identified

& Inspect

K19 K 21 Barnes Neck, Wash None identified

& Sanitize
K24 - Product Code Applied None identified

PS8 (C) - CANNING
C2 - Storage & Handling Bacterial contamination PP Premises (BAC A1.1 &

from leaking roof or pipes BAC A2.1)
C3 C 4 De-palletize / Pallet ID None identified

(Collect & Timestamp Can Pallet
ID, De-palletize)
C6 - Primary code applied None identified

C15 None identified

Pasteurizer


visual) Inspection
C23 C24 Tray Machine & None identified

Code
C25 None identified

Palletize
C27 None identified

Shipping
PS8 T -
TANKERING
T1 - Empty Tanker (Receiving) None identified
T2 - Tanker Washing/ Rinsing None identified
T4 - Tanker Filling/ Loading Insect or pest infestation No pathogens known to survive

of hoses in final product due to
T6 T7 Full Tanker Receiving & Insect or pest infestation No pathogens known to survive
Unloading of hoses in final product due to
Date: Approved by:

FORM 6A:
CHEMICAL HAZARDS
CONTROL & CCPS

Title: Form 6A
BAC Generic Hazard Identification - Chemical Hazards Control & CCPs
List all chemical Identified chemical hazards Controlled at:

hazards related to
ingredients,
incoming
material,
processing,
product flow, etc.
INGREDIENTS
LIQUID INGREDIENTS
City Water Pesticides, Heavy metals PP Premises, Water Quality (BAC

A4.1)
Purchased Water Cleaning chemicals, cross PP - Transportation Receiving &

contamination from previous load Storage (BAC B1.1)
- COA/ Supplier Audits
Well/ Lake/ Pesticides, Heavy metals PP Premises, Water Quality (BAC

Surface/ Water A4.1)
DRY INGREDIENTS
Barley malt Pesticides, Mycotoxins, Allergen PP - Transportation Receiving &

(cross-contamination from carrier), Storage (BAC B1.1)- COA / Letter of
NDMA Guarantee
Wheat (malted/ Pesticides, Mycotoxins, Allergen, PP - Transportation Receiving &

non- NDMA Storage (BAC B1.1)
malte
+ COA / Letter of Guarantee,
d),
Cereal Grain, Pesticides, Mycotoxins, Allergen PP - Transportation Receiving &

e.g. (cross-contamination from carrier), Storage (BAC B1.1)
corn, NDMA
+ COA / Letter of Guarantee,
oats,
rice Allergen Management Program
Hops Pesticides, Mycotoxins PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA

Yeast Heavy Metals, cleaning chemicals PP Transportation, Receiving &

(used in tankers) Storage (BAC B1.1)
+ COA, Wash Tickets
Carbohydrate Antibiotic residue, heavy metal PP Transportation, Receiving &

Matte (honey) Storage (BAC B1.1)
r
(e.g. + COA
sucro
se,
syrup,
honey
)
Salt Non-food grade PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA
Hop Oil Residual solvents, Non-food grade + PP Transportation, Receiving &

Storage (BAC B1.1)
COA
Hop Extract Residual solvents, Non-food grade PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA
Nitrogen/ Chemical non-volatile gases, Non- PP Transportation, Receiving &

Oxygen/ food grade Storage (BAC B1.1)
Compressed Air
+ COA, QC Testing
Purchased CO2
Regenerated Contamination from oil (from the PP - Equipment (BAC C1.2)

CO2 compressor)
Liquid Wheat Allergen Allergen Management Program

Extract
Caramel Non-food grade PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA
Dextrin Non-food grade PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA

Food Enzymes Non-food grade PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA
Stabilizing Heavy metals, Non-food grade PP Transportation, Receiving &

Agents Storage (BAC B1.1)
+ COA
Water Heavy metals, Non-food grade PP Transportation, Receiving &

preparation Storage (BAC B1.1)
agents
+ COA
Preservatives Allergens (Sulphites), Non-food PP Transportation, Receiving &

grade Storage (BAC B1.1)
+ COA,
Yeast Foods Heavy metals, Non-food grade PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA
Processing aids Heavy metals, Non-food grade PP Transportation, Receiving &

Examples Storage (BAC B1.1)
Gelatin, Irish
Moss, Wood + COA
Shavings
Used glass Lubricants, mycotoxins PP Transportation, Receiving &

Storage (BAC B1.1) (Partially
Controlled)
+ Inspection,
+ EBI (Empty Bottle Inspection) /

RLD(Residual Liquid Detector)
Lined aluminum cans None identified

and bottles

PROCESS STEPS
PS1- RECEIVING Chemical Contamination PP Transportation, Receiving &

from truck (damage, leaks, Storage (BAC B1.1)
odors)
PS2- STORAGE/ Chemical - Cross- Allergen Management Program

HANDLING contamination from
allergens (e.g. wheat)
PS3 - BREWING
B3 - Milling Chemical Allergen cross- PP - Sanitation (BAC E1.1)

contamination (e.g. from
residues in the mill) Allergen Management Program

Mash Cooker)
B6 - Lautering (Lauter None identified

Tun, Mash Filter removal
of spent grains

Exchanger)
PS4 -FERMENTATION

F1 Wort Oxygenation/ None identified

Wort Aeration
PROCESS STEPS
F3 - Cooling Coolant leak PP Equipment (BAC C1.2)
PS4 SUB-PROCESS
YEAST PREPARATION
PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling Coolant leak PP Equipment (BAC C1.2)
A5 - Cooling tank Coolant leak PP Equipment (BAC C1.2)
A6 - Aging Tank Coolant leak PP Equipment (BAC C1.2)
A7 - Secondary Storage Coolant leak PP Equipment (BAC C1.2)
Sulphites as an allergen Allergen Management Program
A8 - Surge/ buffer Tank Sulphites as an allergen Allergen Management Program
A9 Filtration Sulphites as an allergen Allergen Management Program
PS6 BRIGHT BEER Coolant leak PP Equipment (BAC C1.2)

STORAGE
Cleaning chemicals PP - Sanitation (BAC E1.1)

PS7 BRIGHT BEER

PROCESSING
PS7 (SF) Sterile

Filtration
SF1 - Bright Beer Tank Coolant leak PP Equipment (BAC C1.2)
SF2 - Filtration Sulphites as an allergen Allergen Management Program
PS7(FP) Flash
Pasteurization
FP1 - Bright Beer Tank Coolant leak PP Equipment (BAC C1.2)
FP2 - Pasteurization Contamination from coolant PP Equipment (BAC C1.2)
PS8 RB
RETURNED BOTTLES
PREP (FLOAT
GLASSWARE PREP)

Inspection (visual)
RB5 - Bottle Wash None identified

Loading
RB7 - Soak Tanks With Too concentrated, too low, PP Equipment (BAC C1.2)
Caustic no caustic, wrong chemical
PP Transportation, Receiving &
Bottle unable to drain Storage (BAC B1.1)

PP Personnel (BAC D1.2) Training
RB8 - Hydro Jet Sprays Bottle unable to drain EBI (Empty Bottle
Inspection)/RLD(Residual Liquid
Detector)
RB9- Post-Soak Bottle unable to drain EBI/RLD
RB12 - Interior Rinse Spray malfunction PP Equipment (BAC C1.2)
Bottle plugged unable to EBI/ RLD

drain
RB13 - Final Rinse Bottle unable to drain EBI/ RLD
PS8 NB -
NEW BOTTLES
(GLASSWARE) PREP

NB3 NB 6 Storage None identified

(Pallet Prep, De-palletize)

visual)
NB9 - Bulk Glass Rinser Contaminated air, sanitizing PP Equipment (BAC C1.2)
spray
PS8 BT - BOTTLING

Failure of the system to (Partially Controlled)
Empty Bottle Inspection detect residual liquid and
(Human or Machine PP Equipment (BAC C1.2)
caustic
inspection) PP Personnel (BAC D1.2) Training
CCP1-C
HUMAN: HUMAN:
Failure of personnel to
detect residual liquid PP Personnel (BAC D1.2) Training
SOP (personnel rotation)

CCP1-C
BT2 Down Bottle Filler None identified

In-Feed Control
BT3 BT5 Filling CIP chemicals in bottle PP - Sanitation (BAC E1.1)

(Purges , Filling, Fobbing)
BT6 - Crowning Lubricants PP Equipment (BAC C1.2)

(Full Bottle Wash -
external)
BT9 None identified

Pasteurize
BT10 - Foam Inspection None identified

&/or Candling
BT11 Drying (Bottle None identified

BT12 BT13 Labelling, Product not coded or not PP - Recall (BAC F1.2)

Inspection

Sealing

Case Pack, Sealing)
BT19 BT20 Secondary Product not coded or not PP - Recall (BAC F1.2)
(Secondary Packaging, PP Equipment (BAC C1.2)
Code/Inspection)

Palletize

Load)

PS8 (K) - KEGGING
K2 K3 Storage & None identified

Handling , De-palletizing
(See PS2)
K5 K6 External Old codes not effectively PP - Recall (BAC F1.2)

Cleaning (Ext removed
Wash/Inspection)
K7 None identified
Racking
K8 K12 Internal Automated Automated

Cleaning (Purge, Flush,
Wash, Purge, Rinse) Cleaning solution not PP - Sanitation (BAC E1.1)
Manual Manual
Cleaning solution not (Partially Controlled)

CCP3-C
K14 K 15 Purge to None identified

Empty & Counter pressure

Sanitize & Inspect
K18 - Filling CIP solution PP - Sanitation (BAC E1.1)


Wash & Sanitize
K24 - Product Code Incorrect or missing code PP - Recall (BAC F1.2)

Applied

PS8 (C) - CANNING
C2 - Storage & Handling Contamination from leaking PP Premises (BAC A1.1 & BAC A2.1)
roof or pipes
C3 C 4 De-palletize / Incorrect or missing code PP - Recall (BAC F1.2)

Pallet ID on pallet
(Collect & Timestamp Can PP Personnel (BAC D1.2) Training

inspection
C6 - Primary code applied Incorrect or missing code PP - Recall (BAC F1.2)
C7 - Bulk in-line rinser Chemicals from PP Premises (BAC A1.1 & BAC A2.1)
compressed air or water

C11 C13 Seaming Chemicals, Lubricants PP Equipment (BAC C1.2)

C15 None identified

Pasteurizer

Inspection

visual) Inspection
C23 C24 Tray Machine Incorrect or missing code PP - Recall (BAC F1.2)
& Code
C25 None identified

Palletize
C26 Storage None identified

(or Live Load)
C27 None identified

Shipping
PS8 T -
TANKERING
T1 - Empty Tanker Cleaning chemicals and/ or PP Transportation, Receiving &

(Receiving) sanitizer Storage (BAC B1.1)
COA, Wash Ticket,
T2 - Tanker Washing/ Cleaning chemicals and/ or PP Equipment (BAC C1.2)

Rinsing sanitizer

T3 - Tanker Purging Contaminated CO2 For Regenerated CO2 PP Equipment

(BAC C1.2)
For Purchased CO2 - PP

Transportation, Receiving & Storage
(BAC B1.1)
COA
T4 - Tanker Filling/ Cross contamination from PP Personnel (BAC D1.2) Training

Loading using hose on non-food
material
T6 T7 Full Tanker Cross contamination with PP Transportation, Receiving &

Receiving & Unloading chemicals from the supplier Storage (BAC B1.1)
Cross contamination from + COA

material PP Personnel (BAC D1.2) Training
Date: Approved by:

FORM 7A:
PHYSICAL HAZARDS
CONTROLS & CCPS

Title: Form 7A
BAC Generic Hazard Identification - Physical Hazards Control & CCPs
List all physical hazards Identified physical Controlled at:

related to ingredients, hazards
incoming material,
processing, product flow,
etc.
INGREDIENTS
LIQUID INGREDIENTS
City Water Silt PP Premises, Water Quality (BAC

A4.1)
Purchased Water None identified
Well/ Lake/ Surface/ Water Silt PP Premises, Water Quality (BAC

A4.1)
DRY INGREDIENTS
Barley malt Glass, Metal PP - Transportation Receiving &

Storage (BAC B1.1) - Receiving
Inspection (screens, magnets)
Wheat (malted/ non- Glass, Metal PP - Transportation Receiving &

malted), Storage (BAC B1.1)

magnets)
Cereal Grain, e.g. corn, Glass, Metal PP - Transportation Receiving &

oats, rice Storage (BAC B1.1)

magnets)
Hops Insects, metal PP - Transportation Receiving &

Storage (BAC B1.1)
+ COA, Inspection

OTHER INGREDIENTS
Yeast None identified PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA, Wash Tickets
Carbohydrate Matter None identified PP Transportation, Receiving &

(e.g. sucrose, Storage (BAC B1.1)
syrup, honey)
+ COA
Salt Rocks (Partially Controlled)

Storage (BAC B1.1)
+ Inspection
Hop Oil Plastic PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA, Inspection
Hop Extract Plastic PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA, Inspection
Nitrogen/ Oxygen/ None identified

Compressed Air
Purchased CO2
Liquid Wheat Extract Plastic (from packaging) PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA
Caramel Plastic (from container) PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA
Dextrin Plastic (from container) PP Transportation, Receiving &

Storage (BAC B1.1)
+ COA

Preservatives None identified
Yeast Foods None identified
Processing aids None identified

Examples Gelatin, Irish
Moss, Wood Shavings
New glass Critical Glass Defects , (Partially Controlled)

Glass
Storage (BAC B1.1)
+COA, Inspection
+ EBI (Empty Bottle Inspection)
Used glass Critical Glass Defects , Dirt, + Bottle Wash

Dust, Glass, Syringes,
Medical Patches, + EBI (Empty Bottle Inspection)
Lined aluminum cans and Metal Shavings (Partially Controlled) PP

bottles Transportation, Receiving & Storage
(BAC B1.1)
+COA
+ Rinse
New Kegs Metal Shavings (Partially Controlled)
Rinse

PROCESS STEPS
PS1- RECEIVING Pests in hoses used for PP Personnel (BAC D1.2)

transferring material, Bulk
Receiving + Training
PS2- STORAGE/ Insect or pest infestation PP - Pest Control (BAC E2.1)

HANDLING
PS3 - BREWING

Mash Cooker)
B6 - Lautering (Lauter None identified

Tun, Mash Filter removal
of spent grains

Exchanger)
PS4 -FERMENTATION
F1 Wort Oxygenation/ None identified

Wort Aeration
F3 - Cooling
PS4 SUB-PROCESS
YEAST PREPARATION

PS5 - AGING/
CLARIFICATION/
FILTRATION
A1 - Cooling
A10 Bright Beer Storage None identified
PS6 BRIGHT BEER None identified

STORAGE
PS7 BRIGHT BEER

PROCESSING
PS7 (SF) Sterile

Filtration
PS7(FP) Flash
Pasteurization

PS8 RB
RETURNED BOTTLES
PREP (FLOAT
GLASSWARE PREP)
RB1 - Receiving/ Storage Damage to bottles PP Transportation, Receiving &

Storage (BAC B1.1)
RB2 - De-palletizing Damage to bottles PP Equipment (BAC C1.2)

Storage (BAC B1.1)
RB3- RB4 - De-casing & Damage to bottles PP Equipment (BAC C1.2)

Inspection (visual)
RB5 - Bottle Wash Damage to bottles PP Equipment (BAC C1.2)

Loading
RB6 - Pre-rinse sprays Damage to bottles (e.g. PP Equipment (BAC C1.2)

Temperature shock due to
storage) PP Transportation, Receiving &
Storage (BAC B1.1)
RB7 - Soak Tanks With Damage to bottles PP Equipment (BAC C1.2)

Caustic
RB8 - Hydro Jet Sprays Damage to bottles, (Partially Controlled)
Bottle contains foreign object PP Equipment (BAC C1.2)

(spray malfunction)

(plugged but sprays cannot
clear object) +EBI
RB9- Post-Soak Damage to bottles (e.g. (Partially Controlled)

Temperature shock),
Bottle plugged
+EBI

RB10 - External Flush Damage to bottles (e.g. (Partially Controlled)

Temperature shock)
+EBI
RB11 - Ext. Rinse Damage to bottles PP Equipment (BAC C1.2)
(e.g. Temperature shock) PP Personnel (BAC D1.2) Training
+EBI
RB12 - Interior Rinse Damage to bottles PP Equipment (BAC C1.2)

(spray malfunction)
+EBI
clear object)
RB13 - Final Rinse Damage to bottles, PP Equipment (BAC C1.2)

(spray malfunction)
+EBI
clear object)
PS8 NB -
NEW BOTTLES
(GLASSWARE) PREP
NB1- NB2 - Receiving & Damage to bottles PP Transportation, Receiving &

Preliminary Inspection Storage (BAC B1.1)
NB3 NB 6 Storage Damage to bottles PP Equipment (BAC C1.2)

(Pallet Prep, De-palletize)
NB7 Inspection (Human, Missed critical glass defects (Partially Controlled)

visual)
+EBI

NB8 - Bottle Loading, Damage to bottles PP Equipment (BAC C1.2)

NB9 - Bulk Glass Rinser Spray malfunction (e.g. PP Equipment (BAC C1.2)
plugged sprays)
PS8 BT - BOTTLING

Empty Bottle Inspection Failure of the system to (Partially Controlled)
(Human or Machine detect foreign matter, glass
defects, bottle damage PP Equipment (BAC C1.2)
inspection)
CCP1-P
HUMAN: HUMAN:
Failure of personnel to detect (Partially Controlled)
foreign matter, glass defects, PP Personnel (BAC D1.2) Training,
glass damage SOP (personnel rotation)
CCP1-P
BT2 Down Bottle Filler Glass inclusions from PP Equipment (BAC C1.2)
In-Feed Control breakage of down bottle at
filler in-feed PP Personnel (BAC D1.2)
BT3 BT5 Filling Chipping of bottles (e.g. from PP Equipment (BAC C1.2)
(Purges , Filling, Fobbing) filling equipment), glass
inclusion PP Personnel (BAC D1.2) Training
Auto-Flush Auto-Flush
Burst bottle leading to glass (Partially Controlled)

inclusion PP Equipment (BAC C1.2)
Storage (BAC B1.1)
CCP2-P
Manual Flush Manual Flush
Burst bottle leading to glass (Partially Controlled)

inclusion
Storage (BAC B1.1)
+ Foam Inspection

BT6 - Crowning Bottle finish damage (Partially Controlled)

(leading to glass
inclusions) PP Equipment (BAC C1.2)
+ Foam Inspection/ Candling

(Full Bottle Wash -
external)
BT9 None identified

Pasteurize
BT10 - Foam Inspection HUMAN

&/or Candling
Physical Failure to detect PP Personnel (BAC D1.2) Training
foreign matter (including
glass)
T11 Drying (Bottle None identified

BT12 BT13 Labelling, Product not coded or not PP - Recall (BAC F1.2)

Inspection

Sealing
Case Pack, Sealing)
BT19 BT20 Secondary Product not coded, or not PP - Recall (BAC F1.2)
(Secondary Packaging, PP Equipment (BAC C1.2)
Code/Inspection)

Palletize

Load)

PS8 (K) - KEGGING
K2 K3 Storage & None identified

Handling , De-palletizing
(See PS2)
K5 K6 External Old codes not effectively PP - Recall (BAC F1.2)

Cleaning (Ext removed
Wash/Inspection)
K7 None identified
Racking
K8 K12 Internal None identified

Cleaning (Purge, Flush,
Wash, Purge, Rinse)
K14 K 15 Purge to None identified

Empty & Counter pressure

Sanitize & Inspect

Wash & Sanitize
K24 - Product Code Incorrect or missing code PP - Recall (BAC F1.2)

Applied


PS8 (C) - CANNING
C2 - Storage & Handling None identified
C3 C 4 De-palletize / Incorrect or missing code on PP - Recall (BAC F1.2)

Pallet ID pallet
(Collect & Timestamp Can PP Personnel (BAC D1.2) Training

inspection
C6 - Primary code applied Incorrect or missing code PP - Recall (BAC F1.2)

C15 None identified

Pasteurizer

Inspection

visual) Inspection

C23 C24 Tray Machine Incorrect or missing code PP - Recall (BAC F1.2)
& Code
C25 None identified

Palletize
C26 - Storage (or Live None identified

Load)
C27 None identified

Shipping
PS8 T -
TANKERING
T1 - Empty Tanker None identified

(Receiving)
T2 - Tanker Washing/ None identified

Rinsing
T4 - Tanker Filling/ None identified

Loading
T6 T7 Full Tanker None identified

Receiving & Unloading
Date: Approved by:

FORM 9:
HAZARDS NOT CONTROLLED

BY BREWERY

HACCP Plan - Form 9
Title: Form 9 Hazards not Controlled by Brewery

Hazards not controlled by Brewery
Hazards (B = Biological, C=Chemical, P= Physical) Indicate the way the Hazard could be
Addressed (Cooking Instructions,
Public Education, Use Before Date,
etc.)
Hazard Descriptions

FORM 10:
HACCP PLAN

HACCP Plan - Form 10
PRODUCT NAME: BEER
CCP/
Process Hazard Hazard Critical Monitoring Deviation Verification HACCP
Steps Number Description Limits procedures Procedures Procedures Records
Empty Bottle CCP1-P Physical - EBI test Who Packaging If the CCP test fails, Pre-start EBI Test Bottle
Inspection- EBI Failure of the bottle failure Operator/ QA the line is stopped by check Monitoring
(Step BT1) system to personnel Packaging Operator/ completed on Records
detect foreign (i.e. 100% QA. Manager/ system by
matter, glass test bottle Frequency At start Supervisor is electricians. Corrective
defects, bottle rejection) up, hourly and at end notified. Action Records
damage of shift Line
Hold product from Supervisor Verification
Refer to SOP last successful test reviews Records
describing EBI testing. records after
100% inspection of each shift or Product Hold &
The Packaging product since last daily and Inspection
Operator or QA successful test is signs & dates Records
personnel signs and done (accept/ reject records.
dates the EBI Test product). Product
Bottle Monitoring Monthly QA Destruction
Form. Repair/ fix equipment record Records
and verify. review.

CCP/
Empty Bottle CCP1-C Chemical - RLD test Who Packaging If the CCP test fails, Pre-start RLD Test Bottle
Inspection Failure of the bottle failure Operator/ QA the line is stopped by check Monitoring
/Residual Liquid system to personnel Packaging Operator/ completed on Records
Detector detect residual (i.e. 100% QA. Manager/ system by
liquid and test bottle Frequency At start- Supervisor is notified. electricians. Corrective
EBI/RLD caustic rejection) up, hourly and at end Action Records
of shift Hold product from Line
(Step BT1) last successful test Supervisor Verification
Refer to SOP reviews Records
describing RLD Product is discarded. records after
testing. each shift or Product
daily and Destruction
The Packaging signs & dates Records
Operator or QA records.
personnel signs and
dates the RLD Test Monthly QA
Bottle Monitoring record
Form. review.

CCP/
Filling CCP2-P Physical 100% Who Packaging If: Line Auto-Flush

Burst bottle functioning Operator Supervisor Monitoring
(Auto-Flush leading to auto-flush - System failed hourly reviews Records
Only) glass inclusion (That is, the Frequency test records after
flushing each shift or Corrective
(Steps BT 3- spray is on, Hourly test and at end or daily and Action Records
BT5) short fill of production ; bottle signs & dates
cycle, reject - Bottle burst and records.
burst Verification
system did not catch it
pattern to Records
specification). Refer to SOP Auto- Monthly QA
The Operator will:
flush Monitoring record Annual Auto-
Procedure - Shut off line review. flush Validation
Records
Document on Auto- - Run suspect bottles to Annual
Flush Monitoring reject validation of Product Hold &
Form. Sign and date. auto-flush. Inspection
- Flush filler Records
- Hold product from last

successful check
- Re-inspect 100% of
product since last
successful check
(accept / reject
product).

CCP/
Internal CCP3-C Chemical Rinse water Who - Kegging If the CCP fails: QA personnel Keg Cleaning
Cleaning Cleaning visible in Operator will perform a Records
(Manual) solution not sight glass of The Kegging Operator sodium check
effectively test keg. Frequency Start up, notifies the Line on the test Analytical
(Steps K8 K12) removed. *every 24 kegs and at Supervisor and keg from the Results
describes the failure.
No the completion of start of each
detectable kegging operation production Corrective
If the rinse water is not
caustic carry- visible through the sight
run. Action Report
over based Perform a visual check glass and/or the
on for rinse water and phenolphthalein check Sodium in the Verification
phenolphthal phenolphthalein check is positive for caustic test keg Reports
ein check. for caustic carry over (turns pink), the sample must
Kegging Operator meet the CCP Monthly
Refer to SOP for performs 2 additional Canadian Audit
test keg runs and if Drinking
details.
either of the re-test fails
Water CCP Training
a CCP failure has
Note: Frequency of occurred. If both re-test Guidelines of Records
every 24 Kegs is for passes, production may <200mg/L of
example purposes resume. sodium.
only. Frequency
should be determined Production may resume The
based off current when the problem has Supervisor
operations (i.e. rate been corrected and verifies the
and number of bottles confirmed by 2 keg rinse
consecutive test keg reports daily.
produce)
runs.

CCP/
Internal CCP3-C If the CCP failure QA performs

Cleaning occurs during a CCP audit
(Manual) production, production on a monthly
is stopped and all kegs basis.
are put on hold back to
(Steps K8 K12) the last good check.
All held product is 100%

discarded.
Deviations and
Corrective Actions are
recorded on the
Corrective Action
Report by the
Supervisor.
Date: Approved by:

HACCP PLAN
APPENDICES

APPENDIX 1
FORM 3
INFORMATION USED FOR

FLOWCHARTS

Information Used to Create Flowcharts
Major Process Steps (Ps) for Making Beer
INPUT PROCESS STEP/ ID OUTPUT

Dry Ingredients PS1 Receiving
PS2 Storage & Handling
Barley Malt, Wheat Malt, PS3 Brewing - Spent grains (by-

Cereal Grains, Water, Water - Milling product), Hot Water,
Preparation Agents, Hops, - Mashing Trub, Wort, Cold
Other ingredients - Lautering Water
- Kettle
- Whirlpool
- Cooling
Other PS4 Fermentation Yeast, Pitching Yeast

Ingredients( processing
aids), Yeast
Other PS5 Aging Beer, CO2

Ingredients( processing (collection, waste)
aids) - Clarification
- Filtration Bulk Beer
CO2
PS6 Bright Beer Storage
PS7 Bright Beer Processing Bright Beer
Packaging Materials, PS8 Packaging
New Bottles (NB), Returned

Bottles (RB), Kegs, Tankers,
Cans
PS9 Warehousing/Shipping

Ps3 - Brewing
Liquid/ Dry/ Bulk B1 Receiving (See PS1)

Compressed Air
B2 Storage (See PS2)
Barley Malt, Wheat Malt B3 Milling Malt Dust, Grist
Cereal, Prepared B4 Cereal Cooker Cooked Cereal

Brewing Water, Steam
Prepared Brewing B5 Mashing (Mash Mixer, Mash Mash

Water,Steam, Grist Cooker)
Sparge water, Steam B6 Lautering (Lauter Tun, Mash Spent Grains, Sweet
Filter removal of spent grains Water
B7 Holding Tank
Hops, Hop oil, other B8 Kettle

ingredients (eg. syrup),
Steam
B9 Whirlpool/ Centrifuge/ Hot Wort

Tank
Oxygen B10 Wort Cooling (Heat Exchanger) Cooled Wort
Next process - PS4 Fermentation

Ps4 - Fermentation
INPUT PROCESS STEP/ ID OUTPUTS
Oxygen or sterile air, F1 Wort Aerated/ Oxygenated Wort

Oxygenation/
Cold Wort Wort Aeration
Cooled aerated wort, Dry Hop, F2 Fermentation CO2

Pitching yeast (See PS3
Brewing)
(Cooling Step) F3 Cooling Yeast
F4 Green Beer Green Beer,
Next Process PS5 Aging (Primary Storage)
Sub-Process - Yeast Preparation
Yeast Source, New Culture Y1 Propagation Pitching Yeast
Oxygenated Wort, Aerated Wort,

Nutrients
Pitching Yeast Y2 Storage Waste Yeast

(Cooling Step)
Acids, Phosphoric, Sulphuric Y3 Acid Washing Pitching Yeast

Waste Yeast
Next Process F2 Fermentation

Ps5 - Aging/Clarification/Filtration
Green Beer (See A1 Cooling

PS4 - Fermentation)
A2 Buffer Tank
A3 Centrifuge Yeast/ Spent Waste

(by-product)
Processing Aids, A4 Buffer tank CO2

Stabilizers, CO2
Preservatives
A5 Cooling
CO2, Hops A6 Aging Tank Beer, Spent Hops,

CO2
De-aerated Water, A7 Secondary Storage Spent Yeast, CO2

Processing Aids,
Stabilizers, CO2
Preservatives
De-aeration Water, A8 Surge/ buffer Tank CO2

Processing Aids,
Stabilizers, CO2
Preservatives
Caramel and other A9 DE Pre-filter/ Filter Trap/ Sheet Spent DE, Spent
ingredients, Filter/ Membrane Filter/ PVPP Yeast, Spent Hops,
Processing Aids, Filter CO2,
Stabilizers, CO2,
Nitrogen
Preservatives
CO2, De-aerated A10 Bright Beer Storage Bright Beer, O2

Water, Nitrogen
Next Process PS7 Bright Beer Processing

Ps7 - Bright Beer Processing
A Sterile Filtration
Filter Preparation SF1 Bright Beer Effluent

(Membrane Filters, Candle Tank
Filters, Integrity Test, Re-chill)
CIP Chemicals, Steam, Water,

Coolant, Sterile Gases
Bright Beer, CO2 SF2 Sterile Sterile Beer

Filtration
SF3 Sterile Beer

Tank
Next Process PS8 Packaging
B Flash Pasteurization
Bright Beer FP1 Flash Pasteurized Beer

pasteurization
Steam , hot water, coolant, Effluent
CO2
FP2 Pasteurized
Beer Tank
Next Process PS8 Packaging

Packaging Processes - Ps8 (RB)
Returned Bottles Prep (Float Glassware Prep)

Returned (Float) Glassware RB1 Receiving/ Storage
RB2 De-palletizing Pallets, Straps, Film,

Twine
RB3 De-casing Foreign materials,

Scrap cartons, Scrap
Partitions, Damaged
Broken Glass,
crowns
RB4 Human (Visual) Foreign materials,

Inspection Scrap cartons, Scrap
Partitions, Damaged
Broken Glass,
crowns
RB5 Bottle Wash Loading Waste beer, debris
First Post Soak RB6 Pre-rinse sprays Straws, butts, waste

water
Steam, water, chemicals RB7 Soak Tanks With Label pulp, Caustic
Caustic (Sodium Hydroxide),
Plastic
Caustic Solution RB8 Hydro Jet Sprays
Receive Ext Flush RB9 Post-Soak Recovered post soak

(effluent)
Recovered External/ RB10 External Flush Recovered external

Internal flush
Recovered Final Rinse RB11 External and internal Recovered external

Rinse rinse, label pulp
carryover
Potable Water RB12 Interior Final Rinse Recovered final rinse
Potable Water RB13 External Final Rinse Recovered final rinse
Washed Glassware
Next Process PS8 BT - Bottling

Packaging Processes - Ps8 (NB)
New Bottles (Glassware) Prep
New Glassware NB1 Receiving
NB2 Preliminary Inspection Reject loads and

pallets
NB3 Storage
NB4 Collect the Manufacturing Pallet

tags
NB5 Pallet prep Straps, film
NB6 De-palletize Top frame, tier sheet,

pallets
NB7 Visual Inspection Rejects, damaged

glassware
NB8 Bottle Loading
Potable Water, NB9 Bulk Glass Rinser Rinsed glassware

Compressed Air
Rinse Water effluent
Next Process PS8 BT - Bottling

Packaging Processes - Ps8 (BT)
Bottling
Washed and Finished BT1 Empty Bottle Inspection Rejects, Finished

Glass, (New or Float) Water and Lube
Compressed Air,
Conveyor Lubricant,
Conveyor Flush Water,
BT2 Down bottle filler in-feed Rejects

control
CO2, Compressed Air, BT3 Purges & Evacuation & Glass, debris,
Positive Pressure shards
Potable Water, Lube
Water CO2
CO2, Counter pressure BT4 Filling Bottle breakage,

bowl, Bright Beer, Hot
Pressurized Water, Filter CO2
Pressurized Water
BT5 Fobbing Beer foam overflow
Packaging Materials, BT6 Crowning Damaged crowns,

Crowns, Compressed air, water effluent, bottle
City Water flush, breakage, spilled
Lubricants beer
City Water Flush BT7 Crowner Flush (external) Water and beer
effluent
City Water BT8 Filled Bottle wash external Rejects
Water, Steam, Chemicals BT9 Pasteurize Effluent, broken

glass
BT10 Foam Inspection/ Candling Rejects

Inspection

Packaging Processes - Ps8 (BT) (Continued)
Bottling (Continued)
Ambient air blower BT11 Bottle Drying and Air

Knives
Packaging material, BT12 Labelling Bottle breakage,

adhesive, compressed air labels, adhesive,
beer
Packaging material (ink) BT13 Primary Packaging, Coding Inks, Cleaning

Solutions
BT14 Filled Bottle Inspection Rejects
BT15 Divert to packers
Packaging material, BT16 Carton Forming Rejects, damaged

cartons, adhesive,
partitions (inserts)
BT17 Case Packing Bottle breakage,

beer, damage
Packaging Material - BT18 Case Sealing Bottle breakage,

Adhesive beer, damage
Packaging Material Ink BT19 Secondary Packaging Inks, Cleaning

Code Solutions
BT20 Full Case Inspection Rejects
Pallets, Tier sheets, trays, BT21 Palletize Finished Goods

straps, shrink wrap, pallet
ID
Finished Goods BT22 Storage (or Live Load)
BT23 Shipping

Packaging Processes - Ps8 (K)
Kegging
Keg Float, Keg Caps, K1 Receiving (See PS1)

Bright Beer
K2 Storage & Handling (See PS2)
K3 De-palletizing (See PS2)
K4 External Inspection Rejected Kegs
Water & Detergents K5 Ext Wash Dust caps,

labels, effluent
K6 Post Wash Inspection Temporary

storage
Kegs Temperature K7 Racking

Storage
Compressed Air K8 Purge to Empty Waste beer,

rejected kegs
Potable Water K9 Flush Rinsings
Acid Steam & Sodium K10 Wash Drain or recover

Hydroxide
Compressed Air K11 Purge to empty Residual CIP

solution
Heated Water K12 Rinse Rinsings to drain
Steam K13 Sterilize & Hold
CO2 K14 Purge to Empty Residual Water,

CO2
CO2 K15 Counter Pressure CO2
Steam K16 Barnes Neck Sanitize Fill
K17 Inspect Rejected Keg

Packaging Processes - Ps8 (K) (Continued)
Kegging (Continued)
Bright Beer, Clean Kegs K18 Filling Waste Beer

from storage
Steam K19 Sterilize Barnes Neck Condensate
Chlorinated Water K20 Final Rinse Dome Chlorinated

water to drain
Sanitation chemicals K21 Chemical Sanitize Barnes Neck
Packaging Material K22 Dust Cap
Plant air K23 Air Dry
Packaging Material K24 Product Code Applied
K25 In-line weighing
K26 Palletize Full goods

storage
K27 Storage or Live Load
K28 Shipping

Packaging Processes - Ps8 (C)
Canning
Cans, Can ends, Bright C1 Receiving Damaged Cans

Beer (from Ps7)
C2 Storage & Handling
C3 Collect & Timestamp Can Straps (to scrap/

Pallet ID recycle)
C4 De-palletize to mass Pallet, frame (top),

conveyor tier sheet
C5 Online visual inspection Non-conforming

cans (rejects)
Packaging Material (ink) C6 Primary code applied Ink
Treated water filtered C7 Bulk in-line rinser Rinse water 1(Bulk

Rinse discharge
water)
CO2 & Bright beer C8 Filling (pre-evacuation & Open filled cans
beer fill)
Open filled cans & CO2 C9 Bubble breakers CO2
CO2 C10 Under Cover Gassing CO2
Can ends C11 Collect manufacturing lot Paper sleeves to

detail for ends baler
Continuous lubrication C12 Double seaming Excess/ surplus

lube, Beer
C13 Filler valve monitor Reject cans
Rinse water (Bulk Rinse C14 External Can Flush Water to sewer
discharge water)
1
Output from one step may be used as input to another step (indicated by bolded print)

Packaging Processes - Ps8 (C) (Continued)
Canning (Continued)
Heating, City Water, Water C15 Pasteurizer Second cooling

Treatment water to drain
Ambient Air C16 Pre-Blower Station
Compressed Air, Ambient C17 Final Dryer Station

Air
C18 Fill Height Inspection Reject cans
C19 Divert to Packers Finished Cans
Open Format 6s & 8s, Hi- C20 Hi-Cone Machine

Cone Web, Finished
Cans
Closed format 12s & 24s, C21 Case Packers

cartons, Finished Cans
C22 Visual Inspection Rejects, cans, Hi-

cone, cartons
Trays, Hot Melt C23 Tray Machine Reject Trays
Packaging Material (ink) C24 Secondary Code applied Ink
Pallets & Stretch film C25 Transfer to Palletizer Finished Pallets
Finished Pallets C26 Storage (or Live Load)
C27 Shipping

Ps8 (T)
Tankering
INPUT PROCESS STEPS/ ID OUTPUT
T1 Empty Tanker
Caustic Water, Acid T2 Tanker Washing
City Water, CO2 T3 Tanker Purging Clean Tanker, CO2
Bright Beer, Clean T4 Tanker Filling

Tanker
T5 Tanker Shipping
T6 Full Tanker Receiving
T7 Full Tanker Unloading

Other Sub-Process - Co2
(No Flowchart)
Collected CO2 CO1 Increase Pressure (Booster)
CO2 Scrubbers (remove water soluble Water soluble

compounds) compounds
CO3 Carbon Filters - Deodorizer
CO4 Carbon Filters Dust Filters Particulate Material
CO5 Compressor
CO6 Dryers Moisture
CO7 Particulate Filter Particulate Material
CO8 CO2 Condensers
CO2 Purchase CO9 Liquid Storage
CO10 Vaporization
CO11 High Pressure Carbon Filters
CO12 Particulate Filters CO2, Particulate

Material

Other Sub-Process - Water Processing
(No Flowchart)
INPUT PROCESS STEPS OUTPUTS
Water Source City, Well, W2 Purification: Purified Water

Purchased (2)
Reverse Osmosis, UV, Ozonation,
Chlorination, Filtration (Sand, DE,
Activated carbon, multimedia)
Purified Water (2) W3 Storage
Acids, Salts, Steam W4 Brewing Water Preparation, pH Mash Water

adjustments, Salts addition
Purified Water Sparge Water
CO2 W5 De-aeration, Cooling, Carbonation Line Packing or

Push Water
Dilution Water for

High Gravity
CO2

APPENDIX 2
FORM 8
CRITICAL COTNROL
POINTS
(LOW ALCOHOL BEER)

HACCP Plan - Appendix 2
Form 8 Critical Control Points for Low Alcohol Beer
Title: Form 8 Critical Control Points (Low Alcohol Beer)

Incoming Category Determine if fully controlled by Q1. Could a Q2. Is it Q3. Is this Q4. Will a CCP
material/ process and Pre-requisite program. control likely that process subsequen Number
step/ hazards on identified measure(s) contaminati step t step
schematic hazard. *If yes = indicate Pre-requisite be used by on with the specificall eliminate + proceed
diagram Program and proceed to next the operator identified y the to next
identified hazard. at any hazard designed identified identified
process could to hazard or hazard
*If no = proceed to question1 (Q1). step? occur in eliminate/ reduce
excess of reduce likely
If NO = not a the the likely occurrenc
CCP + acceptable occurrenc e to an
identification level or e of the acceptable
on how this could identified level?
hazard will be increase to hazard to
controlled an an If NO = CCP + go to last
before and unacceptab acceptabl column
after the le level? e level?
process If YES =
If NO = not If NO = not a CCP
+ proceed to a CCP + next + identify
the next proceed to question subsequent
identified the next (Q4) step +
hazard identified proceed to
hazard If YES = the next
If YES = CCP + go identified
description + If YES = to last hazard
next question next column
(Q2) question
(Q3)

Form 8 Critical Control Points for Low Alcohol Beer
Process Step (For Low Alcohol Beer Only)
PS3 - AGING/
CLARIFICATION/
FILTRATION
A10 Bright Biological No Yes Yes Yes CCP4-B

Beer Storage Inadequate
pH
adjustment
to control
Clostridia
growth
downstream
Chemical
None
identified
Physical
None
identified
Date: Approved by:

APPENDIX 3
FORM 10
ADDITIONS FOR
LOW ALCOHOL BEER

Form 10 - Additions for Low Alcohol Beer
LOW ALCOHOL BEER ONLY
PRODUCT NAME:
Process CCP/Hazar Hazard Critical Monitoring Deviation Verification HACCP

Steps d Number Description Limits procedures Procedures Procedures Records
Bright Beer CCP4-B Inadequate pH pH <4.5 pH analysis of pH must be less pH analysis performed on each kettle Lab
Storage (Step adjustment to wort in kettle by than 4.4 at kettle wort cooler sample & result reviewed reports
(Note: This
A10) control QA wort sample in by QA manager or designate (if
is an Calibratio
Clostridia kettle greater than pH 4.5 will reprocess and
arbitrary n records
growth recheck)
number. - If pH greater than
downstream Audit
CCP or equal to 4.4 pH analysis performed on each BBT &
records
numbering will add additional result reviewed by QA manager or
will depend acid to kettle & designate (if greater than pH 4.5 will
on the recheck. reprocess and recheck)
number of
- If pH greater than pH analysis performed on each filler
CCPs
or equal to 4.4 start up sample & result reviewed by
found in
QA manager (or QA manager or designate (if greater
individual
designate) than pH 4.5 will dump product)
breweries
notified and a
CCPs) Calibration of pH meter & control
deviation report
checks of 5 samples prior to run.
must be
completed After each production the QA Manager
or designate verifies the calibration
records for BBT approvals.
QA Manager conducts yearly audit of
lab analyses.
Date: Approved by:

APPENDIX 4
DIAGRAMS FOR
HAZARD IDENTIFICATION &
CCP DECISION TREE

Diagrams for Hazard Identification and CCP Decision Tree
Critical Control Points for breweries were determined using the HACCP Decision
Tree. The Decision Tree was first developed by a Codex Alimentarius working
group on HACCP in June 1991.
4.1 Hazard Determination
These questions are to be answered for each potential hazard at each step:
Is the presence of a potential Is the presence of a potential hazard in the

hazard in raw material line or the environment probable?
probable?
YES NO NO YES
No Hazard*
Is an unacceptable level, YES Is an unacceptable

survival, persistence or contamination at this step
increase at this step probable?
probable?
NO NO
YES
No Hazard*
YES
Is reduction, if any at a HAZARD

NO
further step adequate?
* Not a hazard to be controlled at this step.

4.2 CCP Decision Tree
Pre-screening question
Determine if (hazard) fully controlled by Pre-requisite programs. If yes,

indicate Pre-requisite Program(s) and proceed to the next identified
hazard. If no, proceed to Question 1 below.
Q1 Could a control measure(s) be used by the operator at any process step?
No C.M. exists
C.M.(S) exists
Not a CCP. Identify how this hazard will
be controlled before or after the process
and proceed to next identified hazard.
Q2 Is it likely that contamination with the identified hazard could occur in excess of
the acceptable level or could increase to an unacceptable level?
No
Yes
Not a CCP. Proceed to next

identified hazard.
Q3 Is this process step specifically designed to eliminate or reduce the likely

occurance of this identified hazard to an acceptable level?
No Yes = CCP
Q4 Will a subsequent step eliminate the identified hazard or reduce its likely
occurance to an acceptable level?
Yes No = CCP
Not a CCP. Proceed to next identified hazard.

APPENDIX 5
BAC GLASS INCLUSION

REFERENCE

BAC Glass Inclusion Reference
The Critical Control Points for the brewing industry have been identified through
analysis as described in preceding sections.
In 1988, a BAC Glass Integrity Task Force developed a manual entitled Good
Manufacturing Practice on the Prevention of Glass Inclusion in Finished Product.
As its name implies, it was intended to ensure that product entering the market
contained no glass contaminants. The GMP was updated 1998 to deal with
changes in the industry and technology in the last 10 years.
The GMP deals specifically with:
Environmental Controls
Preventive Measures
Regular Maintenance Checks
Prewash Bottle Handling

Preventive Measures
Corrective Measures
Bottle Washing
Preventive Measures
Bottle Conveying Systems

Preventive Measures
Corrective Actions
Washed Bottle Inspection

Inspection Methods
Maintenance Measures
Corrective Measures

BAC Glass Inclusion Reference (Continued)
Filling and Crowning Operations
Corrective Measures for Glass Inclusions
Continual Incident Levels
Filled Bottle Inspections
Uncrowned, Improperly Crowned and Low-Filled Bottles
Foam-Picking
Candling
Filtration
Reaction to Inclusions
Verification and Monitoring for GMP
Written Procedures
Setup and Maintenance Checklists
Production Records
Quality Checklists
Consumer Incidents Correlation
This document will be helpful in developing individual brewery HACCP Programs.

Copies of the manual may be obtained by contacting:
Brewers Association of Canada

100 Queen Street, Suite 650
Ottawa, Ontario K1P 1J9

Telephone: (613) 232-9601 Fax: (613) 232-2283
E-mail: office@brewers.ca

APPENDIX 6
BLANK FORMS 1 - 10

PRODUCT DESCRIPTION
FORM 1
PROCESS/PRODUCT TYPE NAME:
1. Product Name(s)
2. Important Product Characteristics
(Aw, Ph, Preservatives,...)
3. How it is to be Used
4. Packaging
5. Shelf Life
6. Where it will be Sold
7. Labelling Instructions
8. Special Distribution Control
Date: Approved by:

LIST OF PRODUCT INGREDIENTS
AND INCOMING MATERIALS
FORM 2
PRODUCT NAME:
Date: Approved by:

FORM 3
PRODUCT NAME(S):
Date: Approved by:

PLANT SCHEMATIC
FORM 4
PRODUCT NAME(S):
Date: Approved by:

HAZARDS IDENTIFICATION
FORM 5
PRODUCT NAME(S)
List all biological hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED BIOLOGICAL HAZARDS CONTROLLED AT

(Bacteria, Parasites, Viruses...)
Date: Approved by:

FORM 6
PRODUCT NAME(S)
List all chemical hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED CHEMICAL HAZARDS CONTROLLED AT
Date: Approved by:

FORM 7
PRODUCT NAME(S)
List all physical hazards related to ingredients, incoming material, processing, product
flow, etc.
IDENTIFIED PHYSICAL HAZARDS CONTROLLED AT
Date: Approved by:

CCP DETERMINATION
FORM 8
Process Step/ Category and Q1. Could a control Q2. Is it likely that Q3. Is this process Q4. Will a CCP Number
Incoming Material identified Hazard measure(s) be contamination with step specifically subsequent step
used at any the identified designed to eliminate the
process step? hazard could occur eliminate/reduce hazard or reduce
in excess of the the likely its likely
Fully controlled by acceptable level or occurrence of the occurrence to an
Pre-requisite could increase to identified hazard to acceptable level?
program? *If no = not CCP. an unacceptable an acceptable
Identify how this level? level?
hazard will be
controlled before *If no = CCP. Go to
*If yes indicate and and after the last column
proceed to next process and proceed *If no = not CCP. *If no = proceed to
identified hazard to next identified Proceed to next (Q4)
hazard. identified hazard
*If yes = not a CCP.
Identify subsequent *Proceed to the next
*If no proceed to *If yes = CCP. Go to step and proceed to identified hazard
(Q1) *If yes = describe *If yes = proceed to last column the next identified
and proceed to (Q2) (Q3) hazard
Date: Approved by:

APPENDIX 7
REFERENCE LITERATURE

References
Procedures to Implement the Hazard Analysis Critical Control Point System.

International Association of Milk, Food and Environmental Sanitarians, Inc. Ames, Iowa.
1991
Micro-organisms in foods, Book 4. Application of the hazard analysis critical control

point (HACCP) system to ensure microbiological safety and quality. The International
Commission on Microbiological Specifications for Foods (ICMSF). Blackwell Scientific
Publications. Oxford. 1988.
Food Safety Enhancement Program. Volumes 1 - 4. Agriculture Canada. 1993-7.
A Simple Guide to Understanding and Applying The Hazard Analysis Critical Control
Point Concept. 2nd edition. international Life Sciences Institute. 1997
CFIA Generic HACCP Plan Models

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Generic Hazard Analysis

HACCP Principle 1 - Hazard Identification.............................................................9

HACCP Principle 2 - Critical Control Points..........................................................10

HACCP Principle 3 - Critical Limits.......................................................................11

HACCP Principle 4 - Establish Monitoring Procedures........................................11

HACCP Principle 5 - Establish Deviation Procedures..........................................13

HACCP Principle 6 - Establish Verification Procedures.......................................14

HACCP Principle 7 - Establish Record Keeping/Documentation.........................15

BAC Generic HACCP Program.............................................................................17

Form 1: Product/Process Description..................................................................19

Form 2: List of Product Ingredients and Incoming Materials...............................23

Form 3: Process Flow Diagram...........................................................................27

Form 4: Schematic Diagram................................................................................41

Form 5: Hazard Identification Biological Hazards................................................45

Form 6: Hazard Identification Chemical Hazards................................................57

Form 7: Hazard Identification Physical Hazards..................................................69

Form 8: Critical Control Points.............................................................................81

Form 3A: Process Flow Diagram with CCPs.....................................................127

Form 5A: Biological Hazards Control & CCPs...................................................141

BAC Generic HACCP Model

Form 7A: Physical Hazards Controls & CCPs...................................................167

Form 9: Hazards not Controlled by Brewery.....................................................181

Form 10: HACCP Plan.......................................................................................185

HACCP Plan Appendices....................................................................................193

Appendix 1- Form 3 - Information used for Flowcharts......................................195

Appendix 2- Form 8 Critical Control Points.....................................................213

Appendix 3 - Form 10 - Additions for Low Alcohol Beer.....................................217

Appendix 4 Diagrams for Hazard Identification & CCP Decision Tree............221

Appendix 5 BAC Glass Inclusion Reference...................................................225

Appendix 6 Blank Forms 1 - 10.......................................................................229

Appendix 7 Reference Literature.....................................................................243

BAC Generic HACCP Model

The HACCP program is a world-wide recognized systematic and preventative

This document is a working guide to preparing a customized program of hazard

Prior to the development and implementation of a HACCP program,

There are 12 basic steps to implementing a HACCP program. They are:

1. Assemble the HACCP team;

2. Describe the product;

3. Identify intended uses;

4. Construct process Flow Diagram and Plant Schematic;

5. Verify on site the Flow Diagram and Plant Schematic;

BAC Generic HACCP Model

6. List hazards associated with each step (Principle 1);

7. Determine Critical Control Points (Principle 2);

8. Establish Critical Limits (Principle 3);

9. Establish Monitoring Procedures (Principle 4);

10. Establish Deviation Procedures (Principle 5);

11. Establish Verification Procedures (Principle 6); and

12. Establish record keeping/documentation for Principles one through six

BAC Generic HACCP Model

BAC/HACCP Plan Workbook; and

BAC/HACCP Plan Glossary.

Pre-requisite programs should be established before attempting to implement the

Each company will determine the appropriate internal procedures to follow to

BAC Generic HACCP Model